CN1422229A - 预卷曲组件 - Google Patents

预卷曲组件 Download PDF

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CN1422229A
CN1422229A CN01807786A CN01807786A CN1422229A CN 1422229 A CN1422229 A CN 1422229A CN 01807786 A CN01807786 A CN 01807786A CN 01807786 A CN01807786 A CN 01807786A CN 1422229 A CN1422229 A CN 1422229A
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coupling assembling
roll
assembly
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crimping portion
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CN1205093C (zh
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马克·P·德波
詹姆斯·哈里森
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AstenJohnson Inc
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Abstract

本发明公开了包括第一和第二预卷曲部分的连接组件。每一个预卷曲部分都具有许多交替的凹痕(22)和凸处(24)。预卷曲部分通过调整和彼此相对运动来结合，使至少一个第一部分的凸处与至少一个第二部分的凹痕啮合，以及至少一个第二部分的凸处与至少一个第一部分的凹痕啮合。

Description

预卷曲组件
发明背景
本发明涉及连接组件。更具体地说，本发明涉及由预卷曲纱线制造的连接组件。
连接组件以各种形式存在并应用于许多方面。例如，金属线段，无论是涂覆的还是未涂覆的，常用于捻合连接线。例如，所述捻合连接线可用于缝合包装物或袋，或把两个部件连接在一起。连接线的另外形式包括在一端和对置的齿端带有固定部件的带，或类似的东西等，所说的带通过该固定部件接纳并由其固定。这样的连接线常用于服装标签或缆绳的连接线，它们一般是坚固的，所以为将其拆除必须使其断裂。其他连接组件可包括吊钩式或环式接合件，例如Velcro商标固定材料，用来形成可环绕和加固的带。其他连接组件的类型是已知和使用的。
虽然这些连接线中的每一种都已证明在某些应用中是有效的，但每一种都有局限性。例如，某些连接线提供的负载强度很低，其他的在尺寸上受到限制，有些则难以制造或费用高昂，而有些只能在有限范围的环境条件下使用，由于温度、湿度的有害影响或存在污染物的破坏。其他的如果不完全破坏则不能打开，这样就不能重复使用。本发明者已经发现，许多这些限制，即使不是全部，可由单个的连接组件，即由预卷曲材料制造的连接组件予以克服。
预卷曲纱线是已知的。美国专利No.2,377,810；3,567,569；3,836,416；4,661,404；4,974,302；5,187,845；6,045,911；6,058,541；6,079,087和6,088,891都公开了形成预卷曲纱线的方法。这些预卷曲纱线的用途是多方面的。美国专利No.2,377,810；3,567,569和4,661,404公开了制造用于机织和针织合成织物的卷曲纱线的方法，例如具有丝绸外观和羊毛性能的合成织物。美国专利No.3,836,416公开了制造波浪形纱线的方法，这些纱线熔合在一起形成塑性薄片材料。美国专利No.5,187,845公开了生产用于毡层产品的预卷曲纱线的方法。美国专利No.6,058,541和6,079,087分别公开了形成用于牙刷和涂料刷的预卷曲纱线的方法。美国专利No.6,045,911公开了在旋转切割机如草坪修剪机中使用的切刀丝。虽然预卷曲组件都已公开，但这些文献中没有一个教导或提出将预卷曲纱线用作连接组件。
发明概述
本发明涉及由一段具有交替凸处和凹痕的预卷曲部分的材料制造的连接组件。连接组件以所希望的构型排列，并通过调整和捻合两个预卷曲部分到重合状态而结合，因而它们彼此闭锁。连接组件可用于许多消费者的最终用途，例如，缆绳和软管连接线、悬浮天花板连接线、车间吊钩和/或植物撑柱、旗杆标志带、提花纹钉板支架，或作为一般的接合件在捻合连接线或类似的东西可使用的任何地方使用。该组件可为任何所希望的长度，优选由合成材料制造，但也可由金属或其他材料制造。
附图的简要说明
图1是按照本发明的预卷曲组件的侧视图。
图2是有横切端的图1预卷曲组件在捻合前的侧视图。
图3是有捻合端的图1的预卷曲组件的侧视图。
图4是图3捻合部分的等比例分解图。
图5说明本发明的预卷曲组件捻合形成多环组件。
图6说明本发明的预卷曲组件捻合成环形单元。
图7说明两个相互联结的有凹痕的预卷曲组件。
图8说明图1组件的优选制造方法。
优选实施方案的详细描述
本发明将参照附图加以说明，其中同一编号将自始至终代表同一组件。
如这里所使用的，术语“组件”包含单丝、复丝、源于膜的带状开衩，或其他类似电阻丝那样的纱线，术语“卷曲”指组件由一个共同的中心开始的波纹或扭变，这是本领域内所知道的。卷曲可使一个组件与至少一个另外的组件在纺织品的编织过程中进行交织，如通过机织或针织，通过“填塞箱卷曲法”，通过利用适合的模具浇铸或模塑组件，通过热定型或其他方法得到组件。术语“热定型”涉及通过带有热处理或不带有热处理的机械手段将特别的卷曲赋予热塑性组件的工艺，例如，让组件通过冷却的或加热的齿轮、辊或板，或让组件通过齿轮、辊或板后再进行加热或冷却，以便按所希望的方式使其永久形变。术语“预卷曲”指在组件形成产品前对其给予所希望卷曲的处理。如这里所使用的，预卷曲和热定型把具体的尺寸的刻痕给予组件，以使这些组件按所希望的吻合方式交锁在一起。
参照图1，示出了本发明连接组件20的第一个实施方案。连接组件20被预卷曲，使得表面A和B具有一系列交替的凹痕22和凸处24。如图所示，交替的凹痕22和凸处24可沿组件20的全长提供，或仅沿着所希望的部分提供。另外，虽然该说明性的实施方案具有矩形的横截面，见图4，但组件20可具有任何所希望的横截面，如圆形的、椭圆形的或任何多边形的。组件20优选由合成材料制造，如尼龙、聚对苯二甲酸乙二醇酯(PET)和相关的聚合物和共聚物、聚对苯二甲酸丁二醇酯(PBT)、聚苯硫醚(PPS)、聚醚酮(PEEK)、聚对苯二甲酸环己二甲酯(PCTA)，和其他例如在工业用纺织品中使用的聚合物。该组件还可由其他适宜的聚合物材料、金属或具有所希望的性能的其他材料制造。连接组件20可以预切长度供应，也可将其绕在卷轴上，由使用者按具体应用所希望的长度切割使用。
参照图2-4，示出了连接组件20的第一个构型。组件20的两端26、28形成十字形交叉，如图2所示。而后使两端26、28相对彼此旋转，使凹痕22和凸处24彼此对齐并联锁咬合，如图3和4所示。联锁的长度由组件的尺寸、形成组件的材料类型、卷曲的频度、凹痕22和凸处24的宽度和深度以及捻合的面积来控制。凹痕22的深度是从一个凹痕的底部到邻近凸处的顶部的内部距离。凹痕22的宽度是从一个凸处到下一个凸处的内部距离。例如，连接组件在热定型工艺中形成。直径1.4mm圆形原料尼龙单丝被热定型以提供所得到的组件，该组件一般具有矩形横截面，大致为0.95mm厚×1.95mm宽。已经发现，3和3.5mm之间的卷曲变形(一个凸处的外表面和对面一个凸处的外表面之间的距离)和3-4个刻痕/cm的卷曲频度提供了所希望的结果。其他材料和构型也可使用，例如，具有不同卷曲间隔和尺寸的材料。
为得到高连接强度，接收凹痕的宽度和深度优选近似等于矩形或非圆形组件的宽度和深度，或圆形组件的直径。这样的凹痕必定固牢组件纱线，并可减少所不希望的永久性松弛的出现。
如图2-4说明捻合的连接组件20可用于许多最终应用。例如，它可用作悬浮天花板连接线、电缆连接线、设备挂钩、撑柱连接线、提花纹钉板夹，或在一般需加固的地方使用捻合连接线或类似的连接线。另外，因为有许多材料可使用，所以由尼龙或类似材料制造的组件20可在高温应用中使用，如电机设备中使用的电缆或蛇管连接线。
另一个接结的构型示于图5。在这个例子中，组件20在多处32a、32b和32c捻合，从而确定多个连接线圈30a、30b和30c。这样的构型可使几个物体由单一的连接组件20连接起来。连接线圈30的任何数目和构型都可确定。另外，这样的柔韧性使组件20可以各种方式使用，例如，设备挂钩等。
另一个接结的构型示于图6和7。参照图6，组件20的每一端26、28用组件20本体捻合，以形成一般的圆环。纱端26、28被捻合的程度是可改变的，这可通过比较图6和7看清楚。如图7所示，多个环可彼此连接起来以形成连结链或类似的链。环形的组件具有惊人的强度。
在一个试验中，两根1 2英寸的预卷曲组件形成线圈并像图7说明的那样连接。预卷曲组件由上面描述的直径1.4mm的圆形聚酰胺6单丝形成，而后被卷曲成3-4凹痕/cm的3-3.5mm的变形。由每一个对置端26、28通过捻合2英寸长的组件20形成线圈。而后利用英斯特朗电子强力测试仪将这两个线圈拉开。大约需要11kg的力才能使组件20连接区域的凹痕和凸处开始滑动和拉开。
作为比较，将两根1/2英寸宽11英寸长的Velcro带连接材料以类似的方式连接，使大约两英寸的材料重叠。该试验中使用的材料是Ultra-Mate品牌的接合件，部件号161293 HTH 1/2in.x11in.打孔的带材。两个Velcro线圈按“图8”构型由上面描述的预卷曲组件连接。而后Velcro线圈利用相同的英斯特朗电子强力测试仪拉开。拉开Velcro线圈所需的力大约也是11kg。
如该试验说明的那样，捻合的预卷曲组件20具有与Velcro线圈相同的强度，虽然它们的尺寸和沿每个线圈的结合区域都小得多。
在每一个接结的构型中，通过退捻纱端26和28，连接组件20可被简单的排除。而后组件20可以任何希望的方式再利用。而且，上面所描述的接结构型和应用，只是作为说明目的提出的，不希望构成限制。其他接结的构型和应用都处在本发明的范围内。
形成预卷曲组件的优选方法将参照图8加以描述。使原料40，如未卷曲的聚合物纱，通过对置的成形齿轮50、60，它们分别具有预置的凸处52和凹处54。除使用对置的齿轮外，各种其他装置也是可以使用的，如凸轮、轧花辊或卷曲板。
依据原料、组件的尺寸和所希望的刻痕大小，要求原料40在通过卷曲设备前加热，以便使其变得柔韧。适宜的温度可对每个聚合物进行选择，对原料40来说，优选加热到接近该聚合物的玻璃化转变温度。对某些聚合物来说，例如，PET，加热是不必要的和所不希望的。在优选的实施方案中，热源46放置在最接近齿轮50、60的地方，并对其控制以提供所希望的热量。各种热源46都可使用，包括热水浴、传导烘箱和对流烘箱、微波辐射和红外辐射。另外，齿轮50、60可被加热，例如，使用筒式加热器或其他适宜的热源，以便随着原料40的被卷曲对其加热。另外，在需要或不需要另外加热的半加热状态，原料40可由用于成形的装置，如喷丝板或挤压机，直接进入齿轮50、60。
如果加热了，卷曲组件48优选通过适宜的方法快速冷却，以便确保卷曲的尺寸和形状得以保留。在一个实施方案中，加热的卷曲组件48通过一个冷水浴或涡流冷冻装置49。另外，主齿轮50、60或补充齿轮(未示出)可被冷却，如通过涡流冷冻装置，以冷却挤出的组件48。如果使用第二组冷却的齿轮装置或类似的装置，它具有与第一组齿轮凹凸相补偿的凸处和凹处，齿轮的运动是协调的。在某些应用中，快速冷却是不必要的，可将组件放置和自然冷却。
而后，完成卷曲的组件48或盘卷成适宜的包装，用户在以后按所希望的长度切割使用，或将该组件切割成预先确定的长度再包装。

Claims (16)

1.包含第一和第二预卷曲部分的连接组件，每一部分都具有许多交替的凹痕和凸处，从而可通过彼此对准和相对运动将预卷曲部分结合，以使至少一个第一部分的凸处与至少一个第二部分的凹痕啮合，以及至少一个第二部分的凸处与至少一个第一部分的凹痕啮合。
2.权利要求1的连接组件，其中包括聚合物材料。
3.权利要求2的连接组件，其中聚合物材料至少包括PET、尼龙、PBT、PPO、PPS、PCTA和PEEK中的一个和它们的共聚物。
4.权利要求1的连接组件，其中该组件具有的横截面形状选自圆形、椭圆形、三角形、长方形、正方形和梯形。
5.权利要求1的连接组件，其中该组件包含的纱选自单丝、复丝、双组分纱和细纱。
6.权利要求1的连接组件，其中预卷曲部分是热定型的。
7.权利要求1的连接组件，其中预卷曲部分是模塑的。
8.连接物体的方法，该方法包括以下步骤：
提供包含第一和第二预卷曲部分的连接组件，每一部分都具有许多交替的凹痕和凸处，
相对要连接的物体放置该组件；
使预卷曲部分对准；和
使预卷曲部分彼此相对运动，使得至少一个第一部分的凸处与至少一个第二部分的凹痕啮合，以及至少一个第二部分的凸处与至少一个第一部分的凹痕啮合。
9.形成连接组件的方法，该方法包括以下步骤：
提供具有一定长度和高度的原料，其长度要大于高度；和
沿该原料的长度在至少两处的高度上卷曲所述原料。
10.权利要求9的方法，其中卷曲是通过原料的热定型完成的。
11.权利要求10的方法，其中热定型工艺包括使原料通过齿轮、轧辊或轧板之间。
12.权利要求10的方法，其中该工艺包括模塑或浇铸原材料。
13.权利要求11的方法，其中齿轮、轧辊或轧板是加热的。
14.权利要求10的方法，其中齿轮、轧辊或轧板是冷却的。
15.权利要求10的方法，其中原料在通过齿轮、轧辊或轧板之间前被加热。
16.权利要求10的方法，其中原料在通过齿轮、轧辊或轧板之间后被冷却。
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