Patent Description:
In a typical rod rolling mill, as depicted diagrammatically in <FIG>, billets are reheated in a furnace <NUM>. The heated billets are extracted from the furnace and rolled through a roughing mill <NUM>, an intermediate mill <NUM>, and a finishing mill <NUM> followed in some cases by a post finishing block (not shown). The finished products are then directed to a laying head <NUM> (containing a laying head pipe) where they are formed into rings <NUM>. The rings are deposited on a conveyor <NUM> for transport to a reforming station <NUM> where they are gathered into coils. While in transit on the conveyor, the rings can be subjected to controlled cooling designed to achieve selected metallurgical properties.

Over the last several decades, the delivery speeds of rod rolling mills have increased steadily. With the increased speed in delivery of the hot rolled product, the forces exerted on the laying head <NUM> and associated components increases. For example, the laying head <NUM> typically includes a pathway and/or split ring assembly attached to a terminal end of the laying head <NUM>, which assists with the formation of the rings or coils of material. The wearing of the pathway and/or split ring can reduce the ability to deliver a stable ring pattern to the conveyor <NUM>, which can affect the cooling and ultimately the end properties of the product. Replacement of the pathway and/or split-ring is a time consuming and costly issue for a mill.

<CIT>, forming the basis for the preamble of claim <NUM>, describes a laying apparatus for forming rings of a rod-shaped rolled strand having at least part of the cantilevered portion of the lying apparatus cantilevered from the main bearing composed of a material lighter than steel to reduce gravitational sag and increase the resonant frequency, thereby increasing the speed of the strand.

From <CIT>a laying head for forming an axially moving hot rolled product into a helical series of rings is known. The laying comprises a quill rotatable about an axis, with a tubular body journalled for rotation between axially spaced bearings, and a nose projecting axially and forwardly from its tubular body. A product guide is carried by the quill. The product guide is configured to form the product into a helical seried of rings. A guide trough provides a helical extension of the product guide. Major portions of the product guide and the guide trough are carried on a continuous helical support on the nose of the quill. The guide trough is channel shaped, with a continuous bottom defining the rim of the helical support, and with segmented detachable side walls.

<CIT> discloses a coil-forming head, defining a longitudinal axis, for forming coils of a substantially rectilinear metallic product, comprising a fixed supporting structure, a rotor, adapted to turn about said longitudinal axis and rotatably fixed to said supporting structure. The rotor comprises a bell-shaped member, which expands outwards with respect to said axis, and has an outer surface thereof provided with at least one spiral-shaped groove, dimensioned to convey and form coils of a metallic product having a diameter from <NUM> to <NUM>, and comprises at least one spiral-shaped tube, arranged inside and integrally fixed to said bell-shaped member, and dimensioned to convey and form coils of a metallic product having a diameter from <NUM> to <NUM>, wherein feeding means are provided to feed the product to said at least one groove or to said at least one tube.

<CIT> deals with a winding apparatus provided for layering of thin elongated material, especially hot-rolled wire in looping-like windings. In the winding apparatus a doubly or spatially curved laying tube whose longitudinal axis forms a cone-shaped rotation body and whose peripheral speed at the outlet opening matches the entrance speed of the material rotates around a rotation axis, in which case the laying tube is also curved in the peripheral direction of the superficides of the rotation body being curved in an essentially concave manner in accordance with a cycloid beginning at the entrance opening of the laying tube with its vertex. The length of the cycloid results from a half-rotation of a rolling circle generated from top to bottom of sais rotation body. The curvature of the laying tube in the peripheral direction of the super ficies is specified by a simultaneously occurring substantially half-rotation of said rotation body around its rotation axis.

<CIT> describes a rolling mill laying head as a quill supported for rotation about its longitudinal axis between axially spaced first and second bearing assemblies. A laying pipe is carried by the quill for rotation therewith. The laying pipe has an entry section lying on the quill axis between the first and second bearing assemblies, and three dimensionally curved intermediate section extending through and beyond the second bearing assembly to terminate at a delivery end spaced radially from the quill axis to define a circular path of travel. The dimesnion by which the laying pipe extends beyond the second bearing assembly is less than the diameter of the circular path.

The industry continues to demand improvements in laying heads and pathway designs to reduce mill downtime and reduce potentially hazardous conditions for workers.

A laying head assembly includes a laying pathway defined by a laying head pipe that is supported by a series of support assemblies extending outwardly from a central support structure on a laying head. Each of the support assemblies includes a support structure that is generally shaped like an air foil. As the laying head rotates at high speeds (RPMs), the shape of the support structures can substantially decrease the noise generated by the laying head assembly and can substantially decrease the power consumed by an electric motor coupled thereto. Further, the split ring of the laying head can include a plurality of enclosed segments and a plurality of open, single flanged segments, these segments can substantially reduce wear and tear on the split ring. Moreover, the limited number of support assemblies and segments substantially reduces maintenance time and the removal and replacement of a laying head pipe.

Referring initially to <FIG> and <FIG>, a coil-forming laying head system <NUM> is configured to coil elongated material, M, such as for example hot, rolled steel, rod or rebar, into a helical formation of rings. The elongated material can have a linear velocity or speed S, which may be as high as or greater than approximately <NUM>,<NUM> feet/min (<NUM>/sec), can be received in the coil-forming laying head system <NUM> intake end <NUM>, and can be discharged in a series of continuous coil loops at the discharge end <NUM>, whereupon the coils may be deposited on a conveyor <NUM>. The elongated material, M, can be discharged from the coil-forming system <NUM> by gravity in a helical formation of rings on conveyor <NUM>, aided by the downwardly angled quill rotational axis at the system discharge end <NUM>. A tripper mechanism <NUM> can be configured to pivot about an axis abutting the distal axial side of the laying head shroud <NUM> guide surface. The pivotal axis can be tangential to the laying head shroud <NUM> inner diameter guide surface about a pivotal angle θ. The coiling characteristics of the elongated material, M, and the placement of the helical formation of rings on the conveyor <NUM> can be controlled by varying the pivotal angle θ.

The coil-forming laying head system <NUM> can have a quill <NUM> that can be configured to rotate about an axis <NUM>. More particularly, the quill <NUM> can have a general horn-shaped contour or a bell-shaped contour that is adapted to rotate about the axis <NUM>. The coil-forming laying head system <NUM> may also include a laying head pipe <NUM> and a laying head assembly <NUM>, which may be coupled to the quill <NUM>. The laying head pipe <NUM> and the laying head assembly <NUM> may be configured to rotate about the axis <NUM> with the quill <NUM> during operation. The laying head pipe <NUM> can be coupled to a laying head assembly <NUM> that is, in turn, coupled coaxially to the quill <NUM>, so that all three components rotate synchronously about the quill <NUM> rotational axis <NUM>. In certain embodiments, a supporting structure (not shown) may be included in the coil-forming laying head system <NUM> and may be configured to support the laying head assembly <NUM>. The quill <NUM> rotational speed can be selected based upon, among other factors, the elongated material, M, structural dimensions and material properties, advancement speed S, desired coil diameter and number of tons of elongated material that can be processed by the laying head pipe without undue risk of excessive wear.

The laying head pipe <NUM> can define a hollow elongated cavity adapted to transport the elongated material, M, through its interior cavity. The laying head pipe <NUM> can have a generally helical axial profile of increasing radius, with a first end <NUM> that is aligned with the rotational axis of quill <NUM> and configured to receive the elongated material M, which may be a metal product, which can be formed into a helical formation of rings. As illustrated, the laying head pipe <NUM> can have a proximal portion extending along an axis, a terminal portion displaced radially and axially from the proximal portion, and an intermediate portion extending between the proximal portion and terminal portion in arcuate path. The first end <NUM> can be part of a proximal portion of the laying head pipe <NUM>. The laying head pipe <NUM> can further include a second end <NUM> that can be part of a terminal portion of the laying head pipe <NUM> displaced radially and axially from the proximal portion. The second end <NUM> can be spaced radially outwardly from and generally tangential to the quill <NUM> rotational axis <NUM> and thus discharge the elongated material, M, generally tangentially to the periphery of the rotating quill <NUM>.

In particular, the second end <NUM> (i.e., terminal end) of the laying head pipe <NUM> can terminate at, and be coupled to, an initial end of a pathway <NUM>, and the pathway <NUM> can be coupled to an end of the laying head assembly <NUM>. In particular, as illustrated in <FIG>, while the laying head pipe <NUM> can extend from the first end <NUM> to the second end <NUM> of the coil-forming laying head system <NUM>, the pathway <NUM> can be coupled to the terminal end of the laying head assembly <NUM> and extend axially in the direction of the axis <NUM> for a fraction of the full length of the laying head assembly <NUM>.

The pathway <NUM> can be configured to control the tail end of the material, M, as it is exiting the laying head pipe <NUM> and define the final shape of the rings or coils of material, M, to be formed. As the elongated material, M, is advanced through the pathway <NUM> it may be conformed into a helical formation of rings. The pathway <NUM> can be coupled to the laying head assembly <NUM> and configured to rotate coaxially with the quill <NUM>. The rotational speed of the quill <NUM> and the pathway <NUM> is substantially the same as the advancement speed, S, of the elongated material, M, such that there may be essentially no linear motion speed between the pathway <NUM> and the elongated material, M, which may facilitate less wear of the inner surfaces of the pathway <NUM> that contact the elongated material, M.

In some embodiments and as shown in <FIG>, the coil-forming laying head system <NUM> may include a laying head shroud <NUM>, which may have an inner diameter that is coaxial with the quill <NUM> rotational axis <NUM> and circumscribes the second end <NUM> of the laying head pipe <NUM> and the pathway <NUM>. Depending upon the structure of the pathway <NUM>, the laying head shroud <NUM> may counteract a centrifugal force imparted on the elongated material, M, Aas it is discharged from the laying head pipe <NUM> by radially restraining the elongated material, M, within the inner diameter surface of the laying head shroud <NUM>. In an embodiment, while the laying head pipe <NUM> and the laying head assembly <NUM> are configured to rotate about the axis <NUM>, the laying head shroud <NUM> is stationary, such that it does not rotate about the axis <NUM>. In a more particular embodiment, the coil-forming laying head system <NUM> may be formed such that it does not include a laying head shroud <NUM>, but only a pathway <NUM> having a particular shape and construction that is sufficient to contain the elongated material, M, as it is discharged from the coil-forming laying head system <NUM> at the end of the pathway <NUM>.

<FIG> includes a front view of the coil-forming laying head system <NUM> in accordance with an embodiment. Notably, the coil-forming laying head system <NUM> can include a pathway <NUM> that can define a channel when viewed in cross-section. <FIG> include perspective and top plan views of the laying head assembly <NUM> and the pathway <NUM> in accordance with embodiments described herein. The pathway <NUM>, in the form of a channel, can generally define a structure having at least one opening extending axially along the length of the pathway <NUM> from a proximal end <NUM> to a terminal end <NUM>. For example, the pathway <NUM>, being in the form or shape of a channel, can define an enclosed conduit, which includes at least one opening. In such embodiments, the opening of the pathway <NUM> may be oriented such that it is adjacent to the split ring <NUM>, such that the combination of the pathway <NUM> (in the shape of a channel) and the split ring <NUM> define an enclosure configured to contain the elongated material, M, within said enclosure.

As further illustrated, the pathway <NUM> can be formed of a plurality of segments <NUM>, which can be coupled to the terminal end of the laying head assembly <NUM>. The plurality of segments <NUM> can be arranged circumferentially around a peripheral edge of the terminal end of the laying head assembly <NUM> to define the pathway <NUM>. The plurality of segments <NUM> may be arranged end-to-end and disposed adjacent to each other to define the pathway <NUM>. In certain instances, it may be feasible to allow for some spacing between two immediately adjacent segments <NUM> of the plurality of segments <NUM>. It will be appreciated that such spacing may be controlled to maintain control of the elongated material, M, within the pathway <NUM>. The plurality of segments <NUM> may be coupled to the laying head assembly <NUM> via fasteners or any other suitable mechanism.

<FIG> includes a sectional front view of the laying head assembly <NUM> and the pathway <NUM> of <FIG> in accordance with an embodiment. Likewise, <FIG> includes detailed sectional front view of the laying head assembly <NUM> and the pathway <NUM>, taken at circle <NUM> of <FIG>, in accordance with an embodiment. The length or circumference through which the pathway <NUM> and each of the segments <NUM> of the plurality of segments <NUM> extends may be controlled to facilitate suitable operation of the system <NUM>. For example, in at least one embodiment, the pathway <NUM> can extend around a periphery of the laying head assembly <NUM> through an angle, α, of less than <NUM>°. The angle, α, can be defined as a central angle created by (<NUM>) a radius C-B that extends from a central point C to the proximal end <NUM> of the pathway <NUM>; and (<NUM>) a radius C-D that extends from the central point C to the terminal end <NUM> of the pathway <NUM>. In another embodiment, the pathway <NUM> can extend around the periphery of the laying head assembly <NUM> through an angle, α, of not greater than <NUM>°, such as not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or even not greater than <NUM>°. In still another non-limiting embodiment, the pathway <NUM> can extend around the periphery of the laying head assembly <NUM> through an angle, α, of at least about <NUM>°, such as at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or at least about <NUM>° or even at least about <NUM>°. It will be appreciated that the pathway <NUM> can extend around the periphery of the laying head assembly <NUM> through any angle, α, within a range including any of the minimum and maximum values noted above.

In another embodiment, each of the segments of the plurality of segments <NUM> can have a particular length relative to each other and a length that defines a portion of the entire length of the pathway <NUM>. For example, in one embodiment, at least one of the segments <NUM> of the plurality of segments <NUM> can extend around the periphery of the laying head assembly <NUM> through an angle, β. The angle, β, can be defined as an angle created by (<NUM>) a radius C-D that extends from the central point C to a first point on the pathway <NUM>; and (<NUM>) a radius C-E that extends from the central point C to a second point on the pathway <NUM>. In another embodiment, at least one of the segments <NUM> of the plurality of segments <NUM> can extend around the periphery of the laying head assembly <NUM> through an angle, β, of at least about <NUM>°, such as at least <NUM>° or at least <NUM>° or at least <NUM>° or at least <NUM>° or at least <NUM>° or at least <NUM>°. In still another non-limiting embodiment, at least one of the segments of the plurality of segments <NUM> can extend around the periphery of the laying head assembly <NUM> through an angle, β, of not greater than <NUM>°, such as not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>° or not greater than <NUM>°. For example, a segment <NUM> of the plurality of segments <NUM> can extend around the periphery of the laying head assembly <NUM> through an angle, β, of at least about <NUM>° and not greater than about <NUM>°, such as an angle, β, of at least about <NUM>° and not greater than about <NUM>°. It will be appreciated that a segment <NUM> of the plurality of segments <NUM> can extend around the periphery of the laying head assembly <NUM> through any angle, β, within a range including any of the minimum and maximum values noted above.

According to one embodiment, each of the segments <NUM> of the plurality of segments <NUM> can have the same length or dimensions relative to each other, which can make them generally interchangeable and facilitate efficient maintenance. In yet another embodiment, any one of the segments <NUM> of the plurality of segments <NUM> can have a different length or dimension relative to each other. For example, it may be suitable that certain segments <NUM> that are exposed to greater wear are shorter or longer as compared to another segment <NUM> of the plurality of segments <NUM> to facilitate efficient maintenance.

As further appreciated from the embodiments illustrated in <FIG>, the pathway <NUM> can define a helical shape having a non-constant radius of curvature. For example, a proximal radius R1 of the pathway <NUM> at the proximal end <NUM> can differ compared to a terminal radius R2 of the pathway at the terminal end <NUM>. The proximal radius R1 can be measured as the radial distance between a center point of the pathway <NUM> at the proximal end <NUM> and an inner surface of the pathway <NUM> at the proximal end <NUM>. As shown in <FIG>, the terminal radius R2 can likewise be measured as the radial distance between a center point <NUM> of the pathway <NUM> at the terminal end <NUM>, which in some embodiments may be the same center point used to measure the proximal radius R1, and a point <NUM> on an inner surface of the pathway <NUM> at the terminal end <NUM>. According to one embodiment, the proximal radius R1 can be less than the terminal radius R2, such that the pathway <NUM> extends around the periphery of the laying head assembly <NUM> and defines a helical shape having an increasing radius of curvature.

In another embodiment (not shown), the proximal radius R1 can be greater than the terminal radius R2, such that the pathway <NUM> extends around the periphery of the laying head assembly <NUM> and defines a helical shape having a decreasing radius of curvature. In a more particular embodiment, the difference in the radius of curvature can be defined as an absolute value of a difference in radius, as measured by the radius of curvature between an initial point (e.g., the proximal radius R1) on the pathway <NUM> and a terminal point (e.g., the terminal radius R2) on the pathway <NUM>. In certain embodiments, the difference in radius can be at least <NUM>%, such as at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>%.

In another non-limiting embodiment, the difference in radius can be not greater than <NUM>%, such as not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or even not greater than <NUM>%. It will be understood that the pathway <NUM> can have a difference in the radius of curvature within a range including any of the minimum and maximum percentages noted above. Changing the radius of curvature of the pathway <NUM> between the proximal end <NUM> and the terminal end <NUM>, such as creating a pathway <NUM> having either an increasing or decreasing radius of curvature, has been noted to reduce the wear of the pathway <NUM> during operations.

Alternatively, the difference in radius of curvature of the pathway <NUM> can be expressed in terms of length (e.g., millimeters or mm). For example, the difference in the radius of curvature, defined as an absolute value of a difference in radius as measured by the radius of curvature between an initial point on the pathway (e.g., the proximal radius R1) and a terminal point on the pathway (e.g., the terminal radius R2) can be at least <NUM>, such as <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or even at least <NUM>. In one non-limiting embodiments, the difference in the radius of curvature can be not greater than <NUM>, such as not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM>. It will be understood that the pathway can have a difference in the radius of curvature within a range including any of the minimum and maximum values noted above, including for example, a difference of radius within a range of at least <NUM> and not greater than <NUM>.

In an embodiment, the pathway <NUM>, being in the form or shape of a channel, can define an enclosed conduit configured to contain the elongated material M. The enclosed conduit can extend axially along the entire length of the pathway <NUM> from the proximal end <NUM> to the terminal end <NUM> and also can extend circumferentially around at least a portion of the second end <NUM> of the laying head assembly <NUM>. As illustrated in <FIG>, the pathway <NUM> can define an enclosed conduit that is enclosed on all sides except at the proximal end <NUM> and at the terminal end <NUM>. <FIG> include different cross-sectional views of an enclosed conduit in accordance with an embodiment. <FIG> are cross-sectional views taken from line A-A in <FIG>.

In a particular aspect, the enclosed conduit <NUM> can include a suitable cross-sectional shape, such as ellipsoidal, circular, polygonal, irregular polygonal, or any combination thereof. For example, the pathway <NUM>, and the enclosed conduit <NUM>, can have a quadrilateral cross-sectional shape as viewed in a plane that is orthogonal to the length of the pathway <NUM> (e.g., along line A-A). In an embodiment, the enclosed conduit <NUM> includes a rectangular cross-sectional shape. In certain embodiments, the cross-sectional shape of the enclosed conduit <NUM> may be selected to reduce the wear of the pathway <NUM> during operations and/or improve the ability of the laying head system <NUM> to deliver a stable ring pattern to the conveyor <NUM>. In such instances where the pathway <NUM> defines an enclosed conduit, a split ring <NUM> may not be necessary, as the pathway <NUM> and the enclosed conduit may be sufficient for fully containing the elongated material, M. Those embodiments utilizing a pathway <NUM> that defines an enclosed conduit can have any of the other features of the pathways described in the embodiments herein.

The enclosed conduit <NUM> can have a particular interior width <NUM> that may define the size of elongated material, M, that can pass therethrough. It will be appreciated that the interior width <NUM> can be an average value taken from multiple randomly placed measurements within the enclosed conduit <NUM>. According to one embodiment, the enclosed conduit <NUM> can have an average interior width <NUM> of at least <NUM>, such as at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM>, Moor at least <NUM>. In one non-limiting embodiment, the average interior width <NUM> of the enclosed conduit <NUM> can be not greater than <NUM>, such as not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM>. It will be appreciated that the enclosed conduit <NUM> can have an average interior width <NUM> within a range including any of the minimum and maximum values noted above.

In certain embodiments, the tail ends of the elongated material, M, can exit from the laying head pipe <NUM> through a pinch roll (not shown), enter the pathway <NUM> at the proximal end <NUM>, traverse the pathway <NUM> by traveling through the enclosed conduit <NUM>, and exit the pathway <NUM> at the terminal end <NUM>. As the elongated material, M, exits the pathway <NUM> at the terminal end <NUM>, a helix of rings of the elongated material, M, are laid down on the conveyor <NUM>. Furthermore, as the elongated material, M, exits the pinch roll and enters the pathway <NUM>, the pathway <NUM> can rotate away from, or backwards to, the direction of rotation of the elongated material, M. For example, if the elongated material, M, is rotating in a clockwise direction about the axis <NUM>, or is exiting the laying head pipe <NUM> at the second end <NUM> such that a helix of rings <NUM> will be laid down on the conveyor <NUM> in a clockwise manner, the pathway <NUM> can rotate in a counterclockwise direction about the axis <NUM>. The elongated material, M, may expand outwardly, in a radial direction, as it exits the pinch roll and enters the pathway <NUM>. Because the pathway <NUM> is rotating away from the elongated material, M, however, a drag force can be exerted on the elongated material, M. The amount of the drag force exerted on the elongated material, M, can be adjusted by altering the internal profile (or cross-sectional shape) of the pathway <NUM> and/or the enclosed conduit <NUM>. For example, the drag force on the elongated material, M, can be lessened if at least a portion of the cross-sectional shape of the pathway <NUM> and/or the enclosed conduit <NUM> is flattened. By contrast, the drag force on the elongated material, M, can be increased if at least a portion of the cross-sectional shape of the pathway and/or the enclosed conduit <NUM> has a "V" shape.

In certain embodiments, as the elongated material, M, exits the pathway <NUM> at the terminal end <NUM>, the elongated material, M, may enter an open trough before being laid down as a helix of rings on the conveyor <NUM>. <FIG> includes a sectional view of an open trough in accordance with an embodiment. The sectional view in <FIG> is taken along line F-F in <FIG>. The open trough <NUM>, also in the form of a channel, can generally define a structure having at least one opening and extending circumferentially around at least a portion of the second end <NUM> of the laying head assembly <NUM>. For example, the open trough <NUM> can be oriented such that it begins adjacent to the terminal end <NUM> of the pathway <NUM> and it ends prior to the proximal end <NUM> of the pathway <NUM>. The open trough <NUM> is open on at least <NUM> side and can define any suitable cross-sectional shape. In an embodiment, the open trough <NUM> is open on two sides and defines one substantially orthogonal angle. In such embodiments, the open trough <NUM> may be oriented such that it is adjacent to the pathway <NUM> and the split ring <NUM>, such that the combination of the open trough <NUM>, the pathway <NUM>, and the split ring <NUM> define an enclosure configured to contain the elongated material, M, within said enclosure until the elongated material, Miss laid down as a helix of rings on the conveyor <NUM>. For example, the elongated material, M, can exit the pathway <NUM> at the terminal end <NUM> and enter the open trough <NUM>. As the elongated material, M, exits the open trough <NUM> at a point before the elongated material, M, would arrive back at the proximal end <NUM> of the pathway <NUM> again, a helix of rings of the elongated material, Mare laid down on the conveyor <NUM>. Like the pathway <NUM>, the open trough <NUM> may also rotate away from, or backwards to, the direction of rotation of the elongated material M. As with the pathway <NUM> and the enclosed conduit <NUM>, the amount of the drag force exerted on the elongated material, M, also can be adjusted by altering the internal profile (or cross-sectional shape) of the open trough <NUM>.

Referring now to <FIG> and <FIG>, another embodiment of a laying head assembly is shown and is generally designated <NUM>. As illustrated, the laying head assembly <NUM> can include a quill <NUM> and a laying head <NUM> coupled thereto along a longitudinal axis <NUM> passing through the center of the laying head assembly <NUM>. Specifically, the quill <NUM> can include a body <NUM> having a proximal end <NUM> and a distal end <NUM>. The distal end <NUM> of the body <NUM> of the quill <NUM> can include a flange <NUM>.

As depicted, the laying head <NUM> can include a central support structure <NUM> that can include a proximal end <NUM> and a distal end <NUM>. The proximal end <NUM> of the central support structure <NUM> of the laying head <NUM> can also include a flange <NUM>. The flange <NUM> of the laying head <NUM> can abut the flange <NUM> of the quill <NUM> and a plurality of bolts <NUM> that can extend through bolt holes in each of the flanges <NUM>, <NUM> can affix the flanges <NUM>, <NUM> to each other. More importantly, the quill <NUM> can be affixed to the laying head <NUM>. <FIG> and <FIG> also show that the laying head <NUM> can include a split ring <NUM> affixed to the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. Details concerning the split ring <NUM> are discussed below.

As best shown in <FIG>, starting closest to the flange <NUM> and moving along the central support structure <NUM> toward the split ring <NUM> the laying head <NUM> can include a first support assembly <NUM> that can extend outwardly from the outer periphery of the central support structure <NUM>. The laying head <NUM> can include a second support assembly <NUM> that can extend outwardly from the outer periphery of the central support structure <NUM>. Further, the laying head <NUM> can include a third support assembly <NUM> that can extend outwardly from the outer periphery of the central support structure <NUM>. The laying head <NUM> can include a fourth support assembly <NUM> that can extend outwardly from the outer periphery of the central support structure <NUM>. Further, the laying head <NUM> can include a fifth support assembly <NUM> that can extend outwardly from the outer periphery of the central support structure <NUM> adjacent to the split ring <NUM> on the laying head <NUM>.

Returning to <FIG>, the laying head <NUM> can also include a peripheral mounting plate <NUM> mounted near an outer periphery of the split ring <NUM>. As shown, the peripheral mounting plate <NUM> can extend over an angle, ANGPMP, and ANGPMP can be less than or equal to <NUM>°. Moreover, ANGPMP can be less than or equal to <NUM>°, such as less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, or less than or equal to <NUM>°. In another aspect, ANGPMP can be greater than or equal to <NUM>°, such as greater than or equal to <NUM>°, greater than or equal to <NUM>°, or less than or equal to <NUM>°. It is to be understood that ANGPMP can be within a range between, and including, any of the values of ANGPMP described herein.

<FIG> further shows that the laying head <NUM> can include a sixth support assembly <NUM> that can extend outwardly from the peripheral mounting plate <NUM> on the split ring <NUM> of the laying head <NUM>. A seventh support assembly <NUM> can extend outwardly from the peripheral mounting plate <NUM> on the split ring <NUM> of the laying head <NUM>. As shown, an eighth support assembly <NUM> can extend outwardly from the peripheral mounting plate <NUM> on the split ring <NUM> of the laying head <NUM>. Further, a ninth support assembly <NUM> can extend outwardly from the peripheral mounting plate <NUM> on the split ring <NUM> of the laying head <NUM>.

Referring now to <FIG> and <FIG>, each of the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM> includes a support structure <NUM> that extends radially outward from the central support structure <NUM> of the laying head <NUM>. Further, each support structure <NUM> is generally perpendicular to the longitudinal axis <NUM> of the laying head assembly <NUM>. As illustrated in <FIG> and <FIG>, each of the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can include a post <NUM> extending from the support structure <NUM>. In a particular aspect, each post <NUM> is integrally formed with the support structure <NUM> so that the post <NUM> is static and does not rotate with respect to the support structure <NUM>. However, each post <NUM> can be formed at an angle, Apost, with respect to the support structure <NUM>, i.e., to a longitudinal axis <NUM> of the support structure, so that the center axis <NUM> of each post <NUM> follows the helical portion of the path of a laying head pathway, described below, that extends through and is supported by the support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. In particular, the post angle, Apost, can be greater than or equal to <NUM>°. Further, Apost can be greater than or equal to <NUM>°, such as greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, or greater than or equal to <NUM>°. In another aspect, Apost can be less than or equal to <NUM>°, such as less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, or less than or equal to <NUM>°. It is to be understood that Apost can be within a range between, and including, any of the values of Apost described herein.

Moreover, it is to be understood that Apost for each of the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can be different. Further, Apost can get progressively smaller from the first support assembly <NUM> to the fifth support assembly <NUM>. Conversely, Apost can get progressively larger from the fifth support assembly <NUM> to the first support assembly <NUM>.

Each post <NUM> of each of the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can be formed with a bore (not visible) therethrough. The bore of each post <NUM> can be substantially perpendicular to the center axis <NUM> of the post <NUM>. <FIG> and <FIG> further indicate that each of the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can include a pipe clamp <NUM> mounted to the post <NUM> using a threaded fastener <NUM>. Each pipe clamp <NUM> is generally U-shaped and can also be formed with a pair of bores (not visible) that can be aligned with the bore on each post <NUM>. The threaded fastener <NUM> can extend through the bores on the post <NUM> and the pipe clamp <NUM> attached thereto. In a particular embodiment, each pipe clamp <NUM> can include a central axis <NUM> and the central axis <NUM> of each pipe clamp <NUM> can be coaxial with a laying head pipe, describe below, that extends through each pipe clamp <NUM>.

Referring now to <FIG> and <FIG>, each of the sixth through ninth support assemblies <NUM>, <NUM>, <NUM>, <NUM> is substantially identical and can include a support structure <NUM> that can extend outwardly from the peripheral mounting plate <NUM> of the split ring <NUM>. In particular, each support structure <NUM> can extend substantially perpendicular to the longitudinal axis <NUM> of the laying head assembly <NUM>. Further, each of the sixth through ninth support assemblies <NUM>, <NUM>, <NUM>, <NUM> can further include a transverse collar <NUM> integrally formed with the support structure <NUM> of each of the sixth through ninth support assemblies <NUM>, <NUM>, <NUM>, <NUM>. Each transverse collar <NUM> is substantially perpendicular to the support structure <NUM> on which the transverse collar <NUM> is formed.

Each transverse collar <NUM> of each of the sixth through ninth support assemblies <NUM>, <NUM>, <NUM>, <NUM> can be formed with a bore (not visible) therethrough. The bore of each transverse collar can be substantially parallel to the longitudinal axis <NUM> of the laying head assembly <NUM>. <FIG> further shows that each of the sixth through ninth support assemblies <NUM>, <NUM>, <NUM>, <NUM> can include a pipe clamp <NUM> mounted to the transverse collar <NUM> using a threaded fastener <NUM>. Each pipe clamp <NUM> is generally U-shaped and can also be formed with a pair of bores (not visible) that can be aligned with the bore on each transverse collar <NUM>. The threaded fastener <NUM> can extend through the bores on the transverse collar <NUM> and the pipe clamp <NUM> attached thereto. In a particular embodiment, each pipe clamp <NUM> can include a central axis extending through a center of the pipe clamp and the central axis of each pipe clamp <NUM> can be coaxial with a laying head pipe, describe below, that extends through each pipe clamp <NUM>.

Referring now to <FIG>, the laying head assembly <NUM> can further include a laying head pipe <NUM> that can extend through an interior <NUM> of the quill <NUM>, an opening <NUM> in the laying head <NUM> that can extend through the flange <NUM> on the proximal end <NUM> of the central support structure <NUM> of the laying head <NUM>, through the pipe clamp <NUM> on the first support assembly <NUM>, through the pipe clamp <NUM> on the second support assembly <NUM>, through the pipe clamp <NUM> on the third support assembly <NUM>, through the pipe clamp <NUM> on the fourth support assembly <NUM>, through the pipe clamp <NUM> on the fifth support assembly <NUM>, through the pipe clamp <NUM> on the sixth support assembly <NUM>, through the pipe clamp <NUM> on the seventh support assembly <NUM>, through the pipe clamp <NUM> on the eighth support assembly <NUM>, and through the pipe clamp <NUM> on the ninth support assembly <NUM>. The laying head pipe <NUM> can terminate at a plurality of segments, described in detail below, mounted around the outer periphery of the split ring <NUM> on the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. It is to be understood that the laying head pipe <NUM> is an enclosed conduit that defines a laying pathway through the interior of the conduit. The laying head pipe <NUM> is configured to contain an elongated material as it moves therethrough.

The laying pathway within the laying head pipe <NUM> can include a proximal portion that can extend along an axis, a terminal portion displaced radially and axially from the proximal portion, and an intermediate portion that can extend between the proximal portion and terminal portion in arcuate path. Moreover, a mill line for forming metal can be coupled to a proximal end of the laying head pipe <NUM> and the laying pathway. In a particular aspect, the laying pathway within the laying head pipe is an elongated hollow pathway configured to receive metal product and form the metal product into a helical formation of rings. Further, in another aspect, the laying pathway can be a hollow body, e.g., the laying head pipe, comprising a metal or metal alloy. The laying head pipe <NUM> and the laying pathway are configured to rotate about the longitudinal axis <NUM> with the laying head <NUM>.

The laying head pipe <NUM>, and laying pathway defined therein, can extend in a tortuous, or helical, path around the central support structure <NUM> of the laying head <NUM>. Moreover, the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can extend from the laying head <NUM> along a tortuous, or helical, path around the central support structure <NUM> of the laying head <NUM>. It can be appreciated that the each of the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM> is attached to the laying head <NUM> at a proximal end of the support assembly <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and attached to the laying head pipe <NUM>, and the laying pathway defined therein, at a terminal end of the support assembly <NUM>, <NUM>, <NUM>, <NUM>, <NUM> opposite the proximal end of the support assembly <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. It can also be appreciated that each of the support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or the support structures <NUM> of each of the support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, can have a different height.

Further, the support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or the support structures <NUM> of each of the support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, can get progressively taller from the first support assembly <NUM> to the fifth support assembly <NUM> as measured from the outer surface of the central support structure <NUM> of the laying head <NUM> to the top of the support assembly <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. In other words, the second support assembly <NUM> is taller than the first support assembly <NUM>; the third support assembly <NUM> is taller than the second support assembly <NUM> and the first support assembly <NUM>; the fourth support assembly <NUM> is taller than the third support assembly <NUM>, the second support assembly <NUM>, and the first support assembly <NUM>; and the fifth support assembly <NUM> is taller than the fourth support assembly <NUM>, the third support assembly <NUM>, the second support assembly <NUM>, and the first support assembly <NUM>.

Conversely, the support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or the support structures <NUM> of each of the support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, can get progressively shorter from the fifth support assembly <NUM> to the first support assembly <NUM> as measured from the outer surface of the central support structure <NUM> of the laying head <NUM> to the top of the support assembly <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. In other words, the fourth support assembly <NUM> is shorter than the fifth support assembly <NUM>; the third support assembly <NUM> is shorter than the fourth support assembly <NUM> and the fifth support assembly <NUM>; the second support assembly <NUM> is shorter than the third support assembly <NUM>, the fourth support assembly <NUM>, and the fifth support assembly <NUM>; and the first support assembly <NUM> is shorter than the second support assembly <NUM>, the third support assembly <NUM>, the fourth support assembly <NUM>, and the fifth support assembly <NUM>.

In a particular aspect, as shown in <FIG>, the support structure <NUM> of each of the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM> is generally shaped like an airfoil (in a top plan view). Each support structure <NUM> can have a rounded leading end <NUM> extending from a central region <NUM> and an elongated trailing end <NUM> extending from the central region <NUM> in a lateral direction, relative to the longitudinal axis <NUM> of the laying head assembly. The trailing end <NUM> can extend in a direction opposite an intended direction of rotating of the laying head assembly <NUM>, the laying head <NUM>, and the laying pathway formed within the laying head pipe <NUM>. As shown, the trailing end <NUM> of each support structure <NUM> can extend for a majority of a total length of the support structure <NUM>. In a particular aspect, the trailing end <NUM> of each support structure <NUM> can have the same contour, or shape. In another aspect, the trailing end of each support structure <NUM> have a different contour, or shape. In another aspect, each support structure <NUM> can have the same cross-sectional shape. Moreover, each support structure <NUM> can have a different cross-sectional shape.

As shown in <FIG>, each support structure <NUM> is oriented so that a longitudinal axis <NUM> of each support structure <NUM> is perpendicular to the longitudinal axis <NUM> of the laying head assembly <NUM> about which the laying head assembly <NUM> can rotate. Additionally, as shown in <FIG>, each support structure <NUM> is oriented so that the leading end <NUM> moves through the air before the trailing end <NUM> as the laying head assembly <NUM> rotates. It is to be understood that the airfoil shape of the support structure <NUM> can be a symmetrical airfoil shape or a cambered airfoil shape. In other words, the cross-sectional shape of the support structure <NUM> can be symmetrical about the longitudinal axis <NUM>. Conversely, the cross-sectional shape of the support structure <NUM> can be asymmetrical about the longitudinal axis <NUM>. Further, the cross-sectional shape of the support structure <NUM> can be asymmetrical about a lateral axis that is perpendicular to the longitudinal axis <NUM>.

The shape and arrangement of the support structures <NUM> can substantially minimize the noise generated by the laying head assembly <NUM> during operation of the laying head assembly <NUM>. This noise reduction can result in a more friendly work environment. Further, the shape and arrangement of the support structures <NUM> can substantially minimize power consumption of a motor coupled to the laying head assembly <NUM> during operation. The reduction in power creates more energy savings for mill operators.

<FIG> indicates that each support structure <NUM> has an overall longitudinal profile area, Along, measured through the longest part of the support structure <NUM> and not including the post <NUM>. Further, each support structure <NUM> can have an overall lateral profile area, Alat, measure through the widest part of the support structure <NUM> and not including the post <NUM>. The ratio Alat/Along is not greater than <NUM>. In a particular aspect, a ratio, Alat/Along, may not be greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM> or not greater than <NUM>. In another aspect, the ratio, Alat/Along, may be at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at last <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at least <NUM> or at last <NUM> or at least <NUM>. It is to be understood that the ratio, Alat/Along, can be within a range between and including any of the maximum and minimum values for the ratio, Alat/Along, described herein.

Referring now to <FIG>, the laying head assembly <NUM> can include a plurality of voids extending between, or within, the plurality of the first through fifth support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. Specifically, the laying head assembly <NUM> can include a first void <NUM> between the flange <NUM> on the proximal end <NUM> of the support structure <NUM> of the laying head <NUM> and the first support assembly <NUM>. Further, the laying head assembly <NUM> can include a second void <NUM> between the first support assembly <NUM> and the second support assembly <NUM>. The laying head assembly <NUM> can also include a third void <NUM> between the second support assembly <NUM> and the third support assembly <NUM>. The laying head assembly <NUM> can include a fourth void <NUM> between the third support assembly <NUM> and the fourth support assembly <NUM>. Moreover, the laying head assembly <NUM> can include a fifth void <NUM> between the fourth support assembly <NUM> and the fifth support assembly <NUM>. As illustrated, the laying head assembly <NUM> can also include a sixth void <NUM> between the fifth support assembly <NUM> and the split ring <NUM> affixed to the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>.

In a particular aspect, at least one of the voids <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or each of the voids <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, can define at least <NUM>% of a total area between the laying head <NUM> and the pathway. Further, the at least one void <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or each of the voids <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, can define at least <NUM>% of the total area or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>% or at least <NUM>%. In another aspect, the at least one void <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or each of the voids <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, can define not greater than <NUM>% of the total area or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>% or not greater than <NUM>%. It can be appreciated that the void % may be within a range between, and including, any of the maximum and minimum void % values described herein.

It can be appreciated that the at least one void <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or each of the voids <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, can be bounded by the laying head <NUM>, the central support structure <NUM> of the laying head <NUM>, the laying head pathway, the laying head pipe <NUM>, one or more of the first through fifth supports <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, the flange <NUM> on the laying head <NUM>, the split ring <NUM> on the laying head <NUM>, or a combination thereof. Moreover, the plurality of voids <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can extend along a tortuous path of the laying head pathway.

It is well understood in the roll mill industry that laying head pipes <NUM> wear out periodically and require changing. It can be appreciated that the limited number of support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and clamps <NUM>, described herein, can allow the laying head pipe <NUM> to be changed much more quickly and easily than in a traditional laying head assembly that typically has a minimum of <NUM> clamps. The present configuration of support assemblies <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and clamps <NUM>, reduces the number of clamping points on the laying head pipe <NUM> without reducing integrity of the laying head assembly <NUM>, functionality of the laying head assembly <NUM>, or durability of the laying head assembly <NUM>. The reduction in clamping points on the laying head pipe <NUM> can save a typical mill operator around <NUM> minutes to fully replace the laying head pipe <NUM>. On average, this is a <NUM>% reduction in the time required to remove and replace the laying head pipe <NUM>. This reduction in time reduces the down time of the roll mill and increases the production of the roll mill.

<FIG> and <FIG> show additional details of the split ring <NUM> and the segments attached to the outer periphery of the split ring <NUM> on the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. As shown in <FIG>, the split ring <NUM> can include a generally cylindrical peripheral wall <NUM> and a generally disc-shaped outer wall <NUM> formed with a split <NUM>. <FIG> shows a generally L-shaped lip <NUM> extending radially outward from the peripheral wall <NUM> of the split ring <NUM> that can form a groove <NUM> around the peripheral wall <NUM> between the peripheral wall <NUM> and a portion of the L-shaped lip <NUM>. <FIG> also shows that the split ring <NUM> can include a generally annular ridge <NUM> that can extend outward from the outer wall <NUM> along a direction parallel to the longitudinal axis <NUM> of the laying head assembly <NUM>.

As shown in <FIG>, the laying head <NUM> can include a first enclosed segment <NUM> affixed to the outer periphery of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. A second enclosed segment <NUM> can be affixed to the outer periphery of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. A third enclosed segment <NUM> can be affixed to the outer periphery of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. Further, a fourth enclosed segment <NUM> affixed to the outer periphery of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. As shown, each enclosed segment <NUM>, <NUM>, <NUM>, <NUM> can be affixed to the outer periphery of the split ring <NUM> on the distal end <NUM> of the central support structure <NUM> of the laying head <NUM> using a pair of threaded fasteners <NUM>.

<FIG> shows that the laying head <NUM> can also include a first open, single flanged segment <NUM> affixed to the outer periphery of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. A second open, single flanged segment <NUM> can be affixed to the outer periphery of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. A third open, single flanged segment <NUM> can be affixed to the outer periphery of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. Further, a fourth open, single flanged segment <NUM> affixed to the outer periphery of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. As shown, each open, single flanged segment <NUM>, <NUM>, <NUM>, <NUM> can be affixed to the outer periphery of the split ring <NUM> on the distal end <NUM> of the central support structure <NUM> of the laying head <NUM> using a pair of threaded fasteners <NUM>.

<FIG> illustrates a cross-sectional view of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. The cross-section is taken through the second enclosed segment <NUM>, however, it is to be understood that each of the enclosed segments <NUM>, <NUM>, <NUM>, <NUM> are substantially identical. As shown in <FIG>, the enclosed segment <NUM> can include an inner wall <NUM> and an outer wall <NUM> connected by an interior lateral member <NUM>. It is to be understood that the inner wall <NUM> and the outer wall <NUM> are substantially perpendicular to the longitudinal axis <NUM> of the laying head assembly <NUM>. Conversely, the interior lateral member <NUM> is substantially parallel to the longitudinal axis <NUM> of the laying head assembly <NUM>. Moreover, the inner wall <NUM> is relatively shorter than the outer wall <NUM>.

As shown, the inner wall <NUM> and the outer wall <NUM> are also connected via an enclosed end <NUM>. As shown, the enclosed end <NUM> can be generally semi-circular in shape as shown in cross-section. However, it can be appreciated that the enclosed end <NUM> can be triangular, rectangular, etc. <FIG> further indicates that the inner wall <NUM> of the second enclosed segment <NUM> can include a lateral flange <NUM> extending therefrom. The lateral flange <NUM> can extend away from the inner wall <NUM> in a direction substantially parallel to the longitudinal axis <NUM> of the laying head assembly <NUM>. The outer wall <NUM> can include a mounting plate <NUM> extending therefrom. The mounting plate <NUM> can extend away from the outer wall <NUM> in the same direction as the lateral flange <NUM>, i.e., substantially parallel to the longitudinal axis <NUM> of the laying head assembly <NUM>.

As illustrated in <FIG>, the enclosed segment <NUM> can engage the outer periphery of the split ring <NUM>. Specifically, the lateral flange <NUM> that extends from the inner wall <NUM> of the enclosed segment <NUM> can fit into the groove <NUM> formed around the split ring <NUM> between the peripheral wall <NUM> and the L-shaped lip <NUM>. Further, the mounting plate <NUM> can fit over the annular ridge <NUM> formed on the outer wall <NUM> of the split ring <NUM> and engage the outer wall <NUM> of the split ring <NUM>. The threaded fastener <NUM> can pass through a bore <NUM> formed in the mounting plate <NUM> of the enclosed segment <NUM> and a bore <NUM> formed in the split ring <NUM>.

<FIG> illustrates a cross-sectional view of the split ring <NUM> of the distal end <NUM> of the central support structure <NUM> of the laying head <NUM>. The cross-section is taken through the second open, single flanged segment <NUM>, however, it is to be understood that each of the open, single flanged segments <NUM>, <NUM>, <NUM>, <NUM> are substantially identical. As shown in <FIG>, the open, single flanged segment <NUM> can include an inner wall <NUM> and an outer wall <NUM> connected by a lateral member <NUM>. It is to be understood that the inner wall <NUM> and the outer wall <NUM> are substantially perpendicular to the longitudinal axis <NUM> of the laying head assembly <NUM>. Conversely, the lateral member <NUM> is substantially parallel to the longitudinal axis <NUM> of the laying head assembly <NUM>. Moreover, the inner wall <NUM> is relatively shorter than the outer wall <NUM>.

As illustrated in <FIG>, the inner wall <NUM> of the second open, single flanged segment <NUM> can include a single radial flange <NUM> extending radially outward from the inner wall <NUM>. Specifically, the single radial flange <NUM> is substantially perpendicular to the longitudinal axis <NUM> of the laying head assembly <NUM>. <FIG> shows that the inner wall <NUM> of the second open, single flanged segment <NUM> can also include a lateral flange <NUM> extending therefrom. The lateral flange <NUM> is substantially perpendicular to the radial flange <NUM> and the lateral flange <NUM> can extend away from the inner wall <NUM> in a direction substantially parallel to the longitudinal axis <NUM> of the laying head assembly <NUM>. As shown, the outer wall <NUM> can include a mounting plate <NUM> extending therefrom. The mounting plate <NUM> can extend away from the outer wall <NUM> in the same direction as the lateral flange <NUM>, i.e., substantially parallel to the longitudinal axis <NUM> of the laying head assembly <NUM>.

As illustrated in <FIG>, the open, single flanged segment <NUM> can engage the outer periphery of the split ring <NUM>. Specifically, the lateral flange <NUM> that extends from the inner wall <NUM> of the open, single flanged segment <NUM> can fit into the groove <NUM> formed around the split ring <NUM> between the peripheral wall <NUM> and the L-shaped lip <NUM>. Further, the mounting plate <NUM> can fit over the annular ridge <NUM> formed on the outer wall <NUM> of the split ring <NUM> and engage the outer wall <NUM> of the split ring <NUM>. The threaded fastener <NUM> can pass through a bore <NUM> formed in the mounting plate <NUM> of the open, single flanged segment <NUM> and a bore <NUM> formed in the split ring <NUM>.

As illustrated in <FIG>, the enclosed segments <NUM>, <NUM>, <NUM>, <NUM>, collectively, can extend along the outer periphery of the split ring <NUM> at an angle, ANGES, and ANGES can be greater than or equal to <NUM>°. Further, ANGES can be greater than or equal to <NUM>°, such as greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, or greater than or equal to <NUM>°. In another aspect, ANGES can be less than or equal to <NUM>°, such as less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, or less than or equal to <NUM>°. It is to be understood that ANGES can be within a range between and including any of the minimum and maximum values of ANGES described herein.

Also, as illustrated in <FIG>, the open, single flanged segments <NUM>, <NUM>, <NUM>, <NUM>, collectively, can extend along the outer periphery of the split ring <NUM> at an angle, ANGOS, and ANGOS can be greater than or equal to <NUM>°. Further, ANGOS can be greater than or equal to <NUM>°, such as greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, greater than or equal to <NUM>°, or greater than or equal to <NUM>°. In another aspect, ANGOS can be less than or equal to <NUM>°, such as less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, less than or equal to <NUM>°, or less than or equal to <NUM>°. It is to be understood that ANGOS can be within a range between and including any of the minimum and maximum values of ANGOS described herein.

It can be appreciated that the laying head pipe <NUM> and the laying pathway therein can extend up to the first enclosed segment <NUM>. A tail end pathway can be defined by the interior of each enclosed segment <NUM>, <NUM>, <NUM>, <NUM> bound by the inner wall <NUM>, the outer wall <NUM>, and the enclosed end <NUM> of each segment <NUM>, <NUM>, <NUM>, <NUM>. Further, the tail end pathway can extend around the open, single flange segments <NUM>, <NUM>, <NUM>, <NUM> along the open, single flange segments <NUM>, <NUM>, <NUM>, <NUM> adjacent to the lateral member <NUM> and radial flange <NUM> of each of the open, single flange segments <NUM>, <NUM>, <NUM>, <NUM>. Accordingly, an elongated material can move through the laying head assembly <NUM>, e.g., through the laying head pipe <NUM> along the laying pathway therein and around the split ring <NUM> through the tail end pathway defined by the enclosed segments <NUM>, <NUM>, <NUM>, <NUM> and the open, single flange segments <NUM>, <NUM>, <NUM>, <NUM>. Thereafter, the elongated material can exit the laying head assembly <NUM> as consecutive rings, or coils, onto the conveyor <NUM> (<FIG>).

The modular segments (enclosed <NUM>, <NUM>, <NUM>, <NUM> and open <NUM>, <NUM>, <NUM>, <NUM>) can allow particular segments to be removed and replaced as they wear or get damaged. The limited number of segments <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> reduces the number of segments substantially, which, in turn, increases the speed in which the segments can be replaced. This reduces down time of the roll mill, which, in turn, can increase production. This reduction in components on the split ring <NUM> also results in a substantial saving in maintenance costs. The segments <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can prevent a wire rod moving through the laying head assembly <NUM> from touching the split ring <NUM>. This substantially reduces wear and tear on the split ring. Moreover, since wear and tear on the split ring <NUM> is reduced, the likelihood of an end of a wire rod passing through the enclosed segments catching on a wear spot or gap and being destroyed is also reduced.

Claim 1:
A laying head assembly (<NUM>; <NUM>) for the formation of coils comprising:
a laying head (<NUM>) configured to rotate about an axis;
a pathway (<NUM>) defining an enclosed conduit (<NUM>) configured to contain an elongated material, the pathway (<NUM>) extending in a helical path around the laying head (<NUM>); and
at least one support structure (<NUM>) coupling the pathway (<NUM>) to the laying head (<NUM>), wherein the at least one support structure (<NUM>) comprises a lateral profile area (Alat), measured through the widest part of the support structure (<NUM>), and a longitudinal profile area (Along), measured through the longest part of the support structure (<NUM>), and wherein the at least one support structure (<NUM>) comprises a ratio [Alat/Along] of not greater than <NUM>,
characterized in that
each support structure (<NUM>) is oriented such that a longitudinal axis (<NUM>) of each support structure (<NUM>) is perpendicular to a longitudinal axis (<NUM>) of the laying head assembly (<NUM>; <NUM>) about which the laying head assembly (<NUM>; <NUM>) rotates, whereby each support structure (<NUM>) shaped as an airfoil is oriented so that a leading end (<NUM>) moves through the air before a trailing end (<NUM>) as the laying head assembly (<NUM>) rotates.