Field of the Invention
[0001] The present invention relates to warp splicing performed as part of a warping method
for warp sample for making short warps used in a fabric sample, and to a method for
warp splicing, which is a preparatory step in weaving.
Background of the Invention
[0002] In Japanese Patent Application Number 10-25994 (title of the invention: Warping Method
for Warp Sample and Warper for Warp Sample, date of application: February 6, 1998),
the applicant presented a warping method for warp sample for producing short warp
for a fabric sample by winding many yarns between separable drums having circumferential
grooves in a ribbon-like fashion.
[0003] The length of the warp sample can freely be changed by changing the spacing between
the drums.
[0004] To make a fabric sample from the sample warp, the step of splicing the end part of
warp sample to the starting part of other warp sample must be repeated while the warp
is wound around a warper drum.
[0005] When a warp beam is switched over in a warp or fabric production process, the step
of splicing the end part of the warp which has been woven to the starting part of
the other warp must be repeated. As disclosed in Unexamined Japanese Patent Application
Publication Number (Tokkai-shou) 60-185848 and Unexamined Japanese Patent Application
Publication Number (Tokkai-hei) 4-100956, to splice warp together, the starting and
end parts of the warps are overlapped and bonded together using a bonding agent (paste,
adhesive, etc.).
[0006] However, bonding the warp together by using a bonding agent does not offer satisfactory
splicing strength.
[0007] It is an object of the present invention to solve the above problem by providing
a warp-splicing method that increases the jointing strength of the splicing part between
the end of one warp and the start of another warp.
Summary of the Invention
[0008] To attain the above object, the present invention provides a warp-splicing method
for splicing the end part of a warp to the starting part of other warp, wherein the
end part of a warp and the starting part of a warp to be spliced are overlapped, the
overlapped warps are pinched using twist bars and moved widthwise with respect to
each other to twist them, and the warps are bonded together using a bonding agent.
[0009] The present invention provides a warp-splicing method, wherein the end part of one
warp and the starting part of the warp to be spliced are each clamped using a clamp,
the warps are overlapped, comb guides that separate the warps from each other are
inserted between the warps, and the warps are twisted together using twist bars.
[0010] The present invention provides a warp-splicing method, wherein the warps between
clangs are spliced by turning the clamps by 90 degrees and positioning bonding-agent
feeders opposite to the clamps across the warps, the clamps are separated, the end
parts of warps pinched by the clamps are pressed along their respective warps, and
the end part of warps are bonded to the warps by feeding a bonding agent from the
bonding-agent feeders.
[0011] The present invention provides a warp-splicing method, wherein the warp is divided
into two groups of odd-numbered and even-numbered, and the end part of the divided
warps and the starting end parts of the other warps are overlapped.
Brief Description of the Drawing
[0012]
Figure 1 is a schematic perspective view illustrating an embodiment according to the
present invention.
Figure 2 is a schematic perspective view illustrating another embodiment of the present
invention.
Figure 3 illustrates a process for splicing end parts of warps according to Figure
1.
Figure 4 illustrates a process for forming a warp sample according to a invention
of a senior application.
Figure 5 is a schematic perspective view showing a state before splicing in an embodiment
of the present invention.
Figure 6 is a schematic perspective view showing a warp which is being cut in an embodiment
of the present invention.
Figure 7 is a schematic perspective view showing a cut warp which is overlapped in
an embodiment of the present invention.
Figure 8 is a schematic perspective view showing a warp which is overlapped in an
embodiment of the present invention, with twisting rollers brought close to the warp.
Figure 9 is a schematic perspective view showing an overlapped warp which is being
introduced between twisting rollers in an embodiment of the present invention.
Figure 10 is a schematic perspective view showing an overlapped warp which is being
twisted together using twisted rollers in an embodiment of the present invention.
Figure 11 is a schematic perspective view showing the next warp which is being twisted
together using twisting rollers in an entodiment of the present invention.
Figure 12 is a schematic perspective view showing all warps which are twisted together
using twisting rollers in an embodiment of the present invention.
Figure 13 is a schematic perspective view showing the relationship between the twisting
rollers and a rotating belt in an embodiment of the present invention.
Figure 14 is a side view of Figure 13.
Detailed Description of the preferred Embodiments
[0013] Referring now to the drawings, a preferred embodiments according to the present invention
are described below.
[0014] First, a warping method for warp sample described in Japanese Patent Application
Number 10-25994 filed by the applicant is outlined by using Figure 4.
[0015] In Figure 4, 10 is a winding unit comprising a pair of separable drums 11 and 12
with peripheral grooves. The drums 11 and 12 have as many peripheral grooves 13 as
the warp formed on them and are adapted so that the drums rotate in synchronization
with each other to wind a yarn Y from a supplying bobbin 14 in a ribbon-like fashion.
[0016] At the circumference of the winding unit 10, a traverse head 15 is provided which
holds the starting end of the yarn Y from the supplying bobbin 14 and moves one pitch
axially every revolution while traveling along the circumference of the winding unit
10.
[0017] Only one supplying bobbin 14 is shown in Figure 4, however, a plurality of supplying
bobbins are actually provided. The traverse head 15 is adapted to hold the yarn Y
front each supplying bobbin 14 and wind it around the winding unit 10 in a ribbon-like
fashion.
[0018] To form a warp 16, the yarn Y from the supplying bobbin 14 is threaded through a
yarn guide 17 and then wound in a ribbon-like fashion over the grooved drums 11 and
12 while being tensioned using the traverse head 15, as shown in Figure 4A. Each yarn
Y fits into the groove 13 in the drums 11 and 12, and for every revolution the traverse
head 15 axially moves as many pitches as the number of yarns Y so as to provide a
predetermined number of warps 16 wound in the axial direction of the drums 11 and
12. After the predetermined number of warps 16 are formed, the drums 11 and 12 are
stopped. Then the warp 16, extending between the drums 11 and 12, is clamped using
a pair of clamps 18, then cut between these clamps 18 by using a cutter 19, and finally
removed from the drums 11 and 12 to form a warp sample 20, as shown in Figure 4D.
[0019] After the warp 16 is removed, the traverse head 15 is returned to its starting position,
the yarn Y is held at its starting tip by the traverse head 15 and threaded through
the yarn guide 17 to resume winding the yarn Y in a ribbon-like fashion, as shown
in Figure 4C.
[0020] Referring now to Figures 1 and 3, the present invention, which is intended to wind
warp sample 20 around a warper drum and splice them together one after another.
[0021] In Figure 1, 21 is a warper drum which feeds warps to a weaving machine and that
splices a warp 16 clamped by clamps 18 into a long warp so that a plurality of fabric
samples can be woven at a time. The warp 16, with its end tip clamped by the clamp
18, is wound around the warper drum 21, and then the clamp 18 is turned by 90 degrees
downward. On the other hand, a clamp 18a on the spliced side of the warp 16a to be
spliced is turned by 90 degrees upward and secured just over the clamp 18, clamping
the warp 16 wound around the warper drum 21, and the warp 16a is threaded at an intermediate
point thereof through a roller 22 and tensioned by suspending a tension weight 23
from a clamp 18b that clamps the end tip of the warp 16a. The end part of the warp
16 wound around the warper drum 21 and the starting part of the warp 16a are twisted
together and bonded.
[0022] Splicing the warp 16 together one after another in the same way allows a plurality
of fabric samples to be woven at the same time.
[0023] Referring to Figure 3, a procedure for splicing the warp 16 is described in detail
below.
[0024] As shown in Figure 3A, the end part 27 of a yarn 26 of the warp 16 wound around the
warper drum side and the starting part 27a of a yarn 26a of the warp 16a to be spliced
are overlapped, and then the yarns 26 and 26a are clamped using the clamps 18 and
18a applied to the warps 16 and 16a, and bonding-agent feeders 28 and 28a are positioned
opposite to each other to clamp the yarns 26 and 26a using the clamp 18a on the starting
side and the bonding-agent feeder 28a and using the clamp 18 on the end part side
and the bonding-agent feeder 28 also.
[0025] To separate the yams 26 and 26a with their starting part 27a and end part 27 overlapped
from each other, comb guides 29 and 29a are inserted between the adjacent yarns 26
and 26a.
[0026] A pair of twist bars 30 is positioned in the middle of the yarns 26 and 26a between
the clamps 18 and 18a, and by moving the twist bars 30 in the opposite widthwise directions,
a twist 31 is applied to the yarns 26 and 26a whose starting part 27a and end part
27 overlap. The twist bars 30 are formed by applying a twist material 33 having a
high coefficient of friction, such as rubber, to a bar body 32. To impart a twist
31 to the yarns 26 and 26a, the twist bars 30 have to be moved in the opposite widthwise
directions only once. To impart another twist 31 to the yarns 26 and 26a, the twist
bars 30 are separated from the yarns 26 and 26a, returned to their original positions,
and moved in the same way as described above. While this is done, the guides 29 and
29a remain inserted between the yarns 26 and 26a to prevent the adjacent yarns 26
and 26a from being entangled when the twist bars 30 applies a twist to the yarns 26
and 26a.
[0027] After the twist 31 is applied to the overlapped end parts 27 and 27a of the yarns
26 and 26a, a main bonding-agent feeding means 34 feed a bonding agent 35 to the end
parts 27 and 27a on both sides of the twist bars 30 to bond the twisted end parts
27 and 27a together.
[0028] As shown in Figure 3C, with end parts 27 and 27a pinched by using the twist bars
30, the clamps 18 and 18a are opened to free an end tip 37 and a starting tip 37a,
thus winding one of the end parts 27 and 27a around the warper drum 21. Because the
other of the end parts is tensioned using the tension weight 23, an excessive twist
is removed, and it is slightly extended. After the claws 18 and 18a place the end
tip 37 and the starting tip 37a along the yarns 26 and 26a, the bonding-agent feeders
28 and 28a feed a bonding agent to bond the end tip 37 and the starting tip 37a to
the yarns 26 and 26a, thus completing the work of splicing together yarn 26 of warp
16 and the yarn 26a of warp 16a together as shown in Figure 3D.
[0029] As described above, according to the present invention, overlapping the end part
27 of the warp 16 and the starting part 27a of the warp 16a, giving the twist 31 to
these parts, and bonding them together and moreover, bonding the end tip 37 of the
end part 27 and the starting tip 37a of the starting part 37 together increases the
splice strength. In addition, bonding the end tip 37 and the starting tip 37a along
the yarns 26 and 26a prevents the splice from posing a problem when the warp is woven
using a weaving machine.
[0030] Referring now to Figure 2, another embodiment according to the present invention
is described.
[0031] The embodiment of Figure 1 is described using an example of splicing the warp 16
to the new warp 16a by winding each yarn 26 of the warp 16 around the warper drum
21 as is. However, if warp 16 has many yarns, this reduces the spacing between the
yarns and makes warp splicing difficult. To prevent this problem, the yarns of the
warp 16 wound around the warper drum 21 are threaded through drums 40o and 40e in
two groups of odd-numbered row 16o and even-numbered row 16e to splice the end parts
of the odd-numbered and even-numbered rows to the warp 16a to be spliced in the same
way as in Figure 3.
[0032] Dividing the warp 16 into two groups of the odd-numbered and even-numbered rows 16o
and 16e facilitates splicing.
[0033] To divide the warp 16 into the odd-numbered row 16o and even-numbered row 16e, the
yarn needs to be clamped using the clamp 18 in two groups of the odd-numbered and
even-numbered rows 16o and 16e when winding the yarn around the winding unit 10 as
shown in Figure 4.
[0034] Conversely, the two groups of the odd-numbered and even-numbered rows of the warp
16, obtained as shown in Figure 4, can be wound around the warper drum 21 to double
the number of yarns of the warp 16.
[0035] Taken together, according to the present invention, twisting and bonding the end
part and starting part of the warp together makes a strong splice when the warp is
wound around a warper drum.
[0036] Referring to the drawings, yet another embodiment according to the present invention
is described below.
[0037] Figure 5 illustrates an example of splicing the starting part of the warp 111 wound
around a warper drum or the like to the end part of the warp 110 supplied to, for
example, a weaving machine. Many warps 110 and 111 are disposed in parallel, and the
warps 110 and 111 are clamped at their ends by using clamps 112, and further clamped
at the distance of a length L predetermined in consideration of the splice length
using intermediate clamps 113. Splicing parts 114 and 115 from the intermediate clamps
113 to the clamps 112 on the end side are installed vertically on a splicing device
(not shown in the drawing), as shown in Figure 5.
[0038] Starting in Figure 5, one warp from each of warps 110a and 111a is mechanically removed
by a conventional leasing method. That is, as shown Figure 6, one warp frown each
of warps 110a and 111a to which the splicing parts 114 and 115 are spliced is cut
by using a cutter 116, immediately under the clamps 112 on the end side. As shown
in Figure 7, the cut yarns Y10 and Y11 are overlapped and held. With the cut warps
kept overlapping, upper and lower twisting rollers 117 and 118 are positioned as shown
in Figure 8, and rotated in opposite directions, as indicated by arrows 119 and 120,
as shown in Figure 9 to introduce the yarns Y10 and Y11 between the twisting rollers
117 and 118. Then the lower twisting roller 118 is rotated in the direction indicated
by the arrow 119, as is the upper twisting roller 117, to twist the yarns Y10 and
Y11 into twisted yarn 121.
[0039] As shown in Figure 11, the yarns Y10 and Y11 of the adjacent warps 110 and 111, twisted
into the twisted yarn 121, are cut and overlapped as explained in Figure 2. The twisting
rollers 117 and 118 are moved one pitch for the warps 110 and 111, being rotated in
opposite directions, as indicated by the arrows 119 and 120, to discharge the twisted
yarn 121. The next yarns Y10 and Y11 are introduced in between the twisting rollers
117 and 118 to twist them as described with reference to Figure 10.
[0040] In the same way as described above, all of warps 110a and 111a are cut successively,
and their yarns Y10 and Y11 are overlapped and twisted into twisted yarn 121 as shown
in Figure 12. As shown in Figure 13, upper and lower rotating belts 122 and 123 are
provided at both ends of the twisted yarn 121 near the upper and lower twisting rollers
117 and 118, though these are omitted in Figures 8 through 12. The rotating belts
122 and 123 move together with the twisting rollers 117 and 118 to pinch the twisted
yarn 121.
[0041] Once the warps 110 and 111 are twisted together, bonding agent is applied to one
yarn or a plurality of yarns of the twisted yarn 121 at one time, using the roller
125 of a bonding agent applicator 124, as shown in Figure 14. Because the spacing
between the warps 110 and 111 is small, at 0.2 mm, bonding agent film is formed between
the twisted yarn 121. Thus, using a bonding agent remover 126, compressed air is blown
to remove excessive bonding agent.
[0042] Then hot air is blown from a dryer 128 against the pasted twisted yarn 121 to dry
the bonding agent, thus providing spliced yarn 130.
[0043] The spliced yarn 130 obtained by applying bonding agent to the spliced yarn 121 and
drying it is successively discharged through the rotating belts 122 and 123. A warp
separating roller 132, provided on the discharge side of the rotating belts 122 and
123, is used to separate the spliced yarn 130 into individual yarns.
[0044] The warp separation roller 132 is adapted so that it has a higher peripheral speed
than, for example, the rotating belts 122 and 123, and thus can remove one yarn of
the spliced yarn pinched between the rotating belts 122 and 123. This makes it possible
to easily separate the pasted yarns of the spliced yarn 130 from each other.
[0045] Taken together, according to the present invention, applying bonding agent to a plurality
of yarns of the twisted yarn which is obtained by overlapping two warps and then twisting
them using upper and lower twisting rollers, removing excessive bonding agent using
compressed air, and drying the yarn enables warp to be spliced quickly without fail.
1. A warp-splicing method for splicing warps together, characterized in that the warps
to be spliced are overlapped and twisted, and bonding agent is applied to the twisted
part to splice the warps.
2. A warp-splicing method according to claim 1 wherein the end part of the warp is spliced
to the starting part of another warp, said method being characterized in that the
end part of a yarn of the warp and the starting part of a yarn of the warp to be spliced
are overlapped, the overlapped yarns of the warps are pinched by using twist bars
and moved in the widthwise direction with respect to each other to twist them, and
the yarns are bonded together by using a bonding agent.
3. A warp-splicing method according to claim 2, wherein the end part of the warp and
the starting part of the warp to be spliced are each clamped by using a clamp, the
yarns of the warps are overlapped, comb guides that separate the yarns from each other
are inserted between the yarns, and the yars are twisted together by using twist bars.
4. A warp-splicing method according to claim 3, wherein the yarns between the clamps
are spliced by turning the clamps by 90 degrees and positioning bonding-agent feeders
opposite to the clamps across the warps, the clamps are separated, the yarn ends pinched
by the clamps are pressed along their respective yarns of the warps, and the yarn
ends are bonded to the yarns by feeding a bonding agent from the bonding-agent feeders.
5. A warp-splicing method according to claim 2, wherein warps are divided into two groups
of odd-numbered warps and even-numbered warps, and the end part of the divided warp
and the starting part of the warp are overlapped to splice them.
6. A warp-splicing method which splices each yarn of warps together, characterized in
that the warps to be spliced together are overlapped on a one-to-one basis and twisted,
bonding agent is applied over a plurality of the warps twisted together, and then
compressed air is blown against the bonding agent surface to remove excessive bonding
agent and dry the warps.
7. A warp-splicing apparatus that splices each yarn of warps, characterized in that it
comprises twisting rollers that twist each overlapped warp, bonding agent applicators
that apply bonding agent to a plurality of the warps, a bonding agent remover that
removes excessive bonding agent applied to the warp using compressed air, a dryer
that dries pasted warps, and upper and lower rotating belts that pinch the warp during
the entire process from twisting to drying.
8. A warp-splicing apparatus according to claim 7, wherein a warp separating roller that
divides the warp into individual warps is disposed on the warp discharge side of the
rotating belts.