Radial contact applicator roll

Details Radial contact applicator roll Radial contact applicator roll

1999-12-29

2002-03-19

Lamb, Brenda A. (Department: 1734)

Coating apparatus

Solid applicator contacting work

With work-handling or work-supporting

C118SDIG001, C118SDIG002

Reexamination Certificate

active

06358317

ABSTRACT:

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
The present invention relates to an applicator roll for applying a liquid composition to the individual fibers of a fan of fibers contacting the roll. More particularly, the present invention relates to an applicator roll for applying a liquid composition to the individual fibers of a fan of fibers contacting the roll, wherein the negative effects of fiber-to-roll contact are minimized.
BACKGROUND OF THE INVENTION
One or more fiberglass strands used, for example, in manufacturing fiberglass-reinforced products, typically are formed by gathering the individual fibers of a fan of glass fibers exiting a glass fiber-forming bushing and by combining the individual glass fibers into one or more strands. A sizing composition is applied, such as, by an applicator roll, to the individual fibers, wherein the sizing composition serves to reduce fiber stress caused by, for example, fiber-to-fiber friction associated with direct fiber-to-fiber contact. The applicator roll typically is cylindrical, is constructed from graphite and is driven to rotate at a modest rotational velocity, as compared to the tangential linear velocity of the fibers as they pass over (and typically contact) the roll.
A sizing composition is applied to the roll, such as, for example, by submerging a portion of the roll into a shallow pool of sizing composition contained within a pan. The roll is then rotated such that the sizing composition is transferred to a position of the roll, whereat the fan of fibers momentarily contact, or Akiss@, the roll and pick up a small quantity of the sizing composition. The amount of sizing applied to the fibers by the applicator roll is controlled, for example, by controlling the rotational velocity of the roll relative to the tangential linear velocity of the fibers as they kiss the roll. U.S. Pat. No. 4,517,916 to Barch, et al. is illustrative of prior art attempts to provide a cylindrical applicator roll for applying a chemical treatment to textile fibers.
With reference to
FIG. 1
, the roll R typically is mounted such that the linear axis C
R
thereof is horizontal, and as such, a point A on the periphery of the roll R travels at a velocity v
A
residing exclusively within a vertical plane P
A
perpendicular to the axis C
R
of the roll R. That is, as roll R rotates about axis C
R
, peripheral points of the roll, being each a fixed distance from the axis C
R
of the roll R, travels at the same linear tangential velocity. For example, point A, located on the periphery of roll R within plane P
A
, travels at velocity v
A
, which is the same as velocity v
C
of point C, which also is located on the periphery of the roll R, but within plane P
C
, which is parallel to, but spaced from, plane P
A
. Moreover, all peripheral point velocities, for example, velocities v
A
, v
B
, v
C
, of points A, B, C, respectively, are of equal magnitude.
Fibers F
1
, F
2
, F
3
, which together form a fiber fan N generally converging from a wide upper end thereof near the glass-forming bushing (not shown) to a narrow lower end thereof near a radial gathering Ashoe@ roll (not shown in FIGS.
1
and
2
), each contact the periphery of applicator roll R, for example, at points A, B, C, respectively, and travel at velocities v
1
, v
2
, v
3
, respectively, towards the gathering shoe. Velocities v
A
, v
B
, v
C
are much smaller than velocities v
1
, v
2
, v
3
, respectively.
With additional reference to
FIG. 2
, and in referring only to point A, fiber velocity v
1
lies in a plane which is oblique to roll point velocity v
A
in a direction towards a centerline axis C
N
of fan N by an angle
1
. Due to point velocity v
A
acting on fiber velocity v
1
, a resultant velocity R
1A
acts on fiber F
1
, oblique to fiber velocity v
1
, in a direction away from fan centerline axis C
N
by angle
1
, thereby urging the fiber F
1
in a direction away from fan centerline C
N
, and resulting in so-called Afiber walking@ of the fiber F
1
towards one end R
1
, R
2
of the roll R. of course, fiber F
1
, which is located between a first end R
1
of roll R and fan centerline C
N
, will walk towards the first end R
1
of roll R, whereas fiber F
3
, which is located between a second end R
2
of roll R and fan centerline C
N
, will walk towards the second end R
2
of roll R. Fiber walking increases fiber-to-fiber abrasion, imparts additional tensile and shear stresses within the fibers, and produces uneven coating of the sizing composition onto the fibers. Thus, it is desirable to provide a roll for applying a liquid composition to the individual fibers of a fan of fibers passing over the roll, wherein fiber walking is minimized.
Moreover, assuming that point B lies in a plane containing fan centerline C
N
, fiber velocity v
2
is coaxial with point velocity v
B
, and a resultant velocity (not shown) between fiber velocity v
2
and point velocity v
B
lies in the plane containing point centerline v
B
,fiber velocity v
2
, and fan centerline C
N
. Fiber F
2
, unlike fibers F
1
and F
3
, then, is not urged away from fan centerline C
N
and does not walk towards either end R
1
, R
2
of roll R. Rather, less tensile stress is induced in fiber F
2
than is induced in fibers F
1
, or F
3
Accordingly, fibers F
1
, F
2
, F
3
of fan N experience varying degrees of tensile stress and walking, depending on the distance of the fibers F
1
,F
2
, F
3
from the fan centerline C
N
. That is, the farther a fiber is from fan centerline, the greater the degree of tensile stress induced therein, and the greater the degree of walking experienced thereby. It is therefore desirable to provide a roll for applying a liquid composition to the individual fibers of a fan of fibers passing over the roll, wherein the negative effects of fiber-to-roll contact are minimized.
Curved rolls are known in the art for specific applications. For example, U.S. Pat. No. 3,500,524 to Jaminas and U.S. Pat. No. 4,805,274 to Gallant, et al. each teaches a roll having an adjustable radial deflection or curvature. However, neither Jaminas >524 nor Gallant >274 teaches an applicator roll for applying a liquid composition to the individual fibers of a fan of fibers passing over the roll, wherein the negative effects of fiber-to-roll contact are minimized.
SUMMARY OF THE INVENTION
The present invention is for an applicator roll used to apply a sizing composition to the individual fibers of a fan of fibers being gathered, for example, into a strand for use in fiberglass-reinforced products. The applicator roll is generally of an arcuate shape and includes a curved shaft and an elastic sleeve covering at least a portion of the shaft. The shaft includes a central axis having a curved center portion defining a radius and linear end portions extending from either end of the curved center portion. The sleeve, which is elastic and resembles a piece of rubber hose, fits over all of shaft curved center portion and over at least a portion of shaft linear end portions, then, includes a center axis which is coincident with the shaft center axis. The applicator roll is part of a sizing delivery system and is positioned adjacent to a sizing delivery assembly and upstream from a gathering shoe.
The sleeve is connected at one end thereof to a drive, which rotates the sleeve around the shaft. The sleeve is positioned relative to a sizing delivery assembly such that an outer surface of the sleeve receives liquid sizing dispensed through a slotted orifice provided in the sizing delivery assembly. Rotation of the sleeve, then, carries the liquid sizing to a location where the individual fibers of the fan of fibers kiss the outer surface of the sleeve and pick up a small quantity of the sizing composition thereby. Excess sizing is collected in a reservoir positioned beneath the roll and is re-circulated back into the sizing delivery assembly.
Because the roll is arcuate, fibers kissing the outer surface of the sleeve are each traveling in a direction which is substantially coaxial with the direction of

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