Yarn storage system and method for producing textiles using such yarn storage system

Abstract

A yarn storage container for storing a yarn, said storage container (101) comprising a, preferably tubular, container (101), having an axial length (L), a, preferably tubular, wall (501) and a first and second axial extremity (113-115), the first axial extremity (113) of said container (101) having an opening (123) for receiving an end of a yarn (200), said second axial extremity (115) of said container (101) being air-permeably closed, said wall (501) is air permeable by means of a plurality of openings (521-523) present along the axial length of said container (101). The invention further relates to a yarn storage system (1000) comprising a plurality of containers (101), to a textile production assembly (2000) and to methods of producing yarn (200) and textiles.

Claims

1. A creeling system, comprising: a yarn storage system, wherein the yarn storage system comprises a plurality of yarn storage containers positioned within the yarn storage system; a first yarn storage container of the plurality of yarn storage containers positioned within the yarn storage system at a horizontal distance and at a vertical distance from a second yarn storage container of the plurality of yarn storage containers positioned within the yarn storage system; a plurality of injectors, wherein: each injector is movably secured to the creeling system, each injector is configured to propel a yarn; a robot comprising a memory and configured to receive and store a filling sequence; and wherein the robot is configured to execute the filling sequence by at least: moving a first injector of the plurality of injectors to a first location proximal the first yarn storage container, activating the first injector for a first duration, moving the first injector to a second location that is the horizontal distance and the vertical distance from the first location, and activating the first injector for a second duration.

2. The creeling system of claim 1, wherein the yarn storage system comprises a transporting system.

3. The creeling system of claim 1, wherein each yarn storage container of the plurality of yarn storage containers comprises a first opening configured to receive the yarn.

4. The creeling system of claim 1, wherein the second location is proximal the second yarn storage container.

5. The creeling system of claim 1, wherein: the creeling system comprises a beam; wherein the beam is configured with slots; and wherein a number of slots on the beam is equal to or greater than a total quantity of yarn storage containers of the plurality of yarn storage containers positioned within the yarn storage system.

6. The creeling system of claim 5, wherein the robot is configured to execute the filling sequence by at least: moving a first injector of the plurality of injectors to a location proximal the first yarn storage container, activating the first injector for a first duration, moving the first injector to a location proximal a first slot on the beam, moving the first injector to a location proximal the second yarn storage container, and activating the first injector for a second duration.

7. The creeling system of claim 1, wherein: the creeling system comprises a rack; wherein the rack comprises a first spool of a plurality of spools; and wherein the first spool comprises the yarn.

8. The creeling system of claim 1, comprising: a third yarn storage container of the plurality of yarn storage containers positioned within the yarn storage system; a fourth yarn storage container of the plurality of yarn storage containers positioned within the yarn storage system; and wherein the robot is configured to execute the filling sequence by at least: moving a first injector of the plurality of injectors to a location proximal the first yarn storage container, activating the first injector for a first duration, moving a second injector of the plurality of injectors to a location proximal the third yarn storage container, activating the second injector for a second duration, moving the first injector to a location proximal the second yarn storage container, activating the first injector for a third duration, moving the second injector to a location proximal the fourth yarn storage container, and activating the second injector for a fourth duration.

9. The creeling system of claim 8, wherein: the creeling system comprises a beam; wherein the beam is configured with slots; wherein a number of slots on the beam is equal to or greater than a total quantity of yarn storage containers of the plurality of yarn storage containers positioned within the yarn storage system; and the creeling system comprises a rack; wherein the rack comprises a first spool and a second spool of a plurality of spools; wherein the first spool comprises the yarn, and the second spool comprises a second yarn.

10. The creeling system of claim 9, wherein the yarn storage system comprises a transporting system.

11. The creeling system of claim 9, wherein the first injector comprises a vortex injector.

12. A creeling system, comprising: a yarn storage system, wherein the yarn storage system comprises a plurality of yarn storage containers positioned within the yarn storage system; a first yarn storage container of the plurality of yarn storage containers positioned within the yarn storage system at a horizontal distance and at a vertical distance from a second yarn storage container of the plurality of yarn storage containers positioned within the yarn storage system; a rack, wherein; the rack comprises a first spool and a second spool of a plurality of spools, the first spool comprises a first yarn, and the second spool comprises a second yarn; a plurality of injectors, wherein each injector is movably secured to the creeling system; a robot comprising a memory and configured to receive and store a filling sequence; wherein the first yarn is loaded into a first injector of the plurality of injectors, and the second yarn is loaded into a second injector of the plurality of injectors; and wherein the robot is configured to execute the filling sequence by at least: moving the first injector to a location proximal the first yarn storage container, propelling a first length of the first yarn into the first yarn storage container, moving the first injector to a location proximal the second yarn storage container, propelling a second length of the first yarn into the second yarn storage container.

13. The creeling system of claim 12, wherein the yarn storage system comprises a transporting system.

14. The creeling system of claim 13, wherein each of the plurality of yarn storage containers comprises a first opening configured to receive the yarn.

15. The creeling system of claim 14, wherein: the creeling system comprises a beam; wherein the beam is configured with slots; and wherein a number of slots on the beam is equal to or greater than a total quantity of yarn storage containers of the plurality of yarn storage containers positioned within the yarn storage system.

16. The creeling system of claim 15, wherein the robot is configured to execute the filling sequence by at least: moving the first injector to a location proximal the first yarn storage container, propelling a first length of the first yarn into the first yarn storage container, moving the first injector to a location proximal a first slot on the beam, moving the first injector to a location proximal the second yarn storage container, propelling a second length of the first yarn into the second yarn storage container.

17. The creeling system of claim 15, wherein the robot is configured to execute the filling sequence by at least: moving the first injector to a location proximal the first yarn storage container, propelling a first length of the first yarn into the first yarn storage container, moving the first injector to a location proximal a first slot on the beam and cutting the first yarn, moving the first injector to a location proximal the second yarn storage container, propelling a second length of the first yarn into the second yarn storage container.

18. The creeling system of claim 12, wherein: the yarn storage system comprises a third yarn storage container positioned within the yarn storage system at a location different from the first yarn storage container and different from the second yarn storage container; and wherein the robot is configured to execute the filling sequence by at least: moving the first injector to a location proximal the first yarn storage container, propelling a first length of the first yarn into the first yarn storage container, moving the second injector to a location proximal the second yarn storage container, propelling a length of the second yarn into the second yarn storage container, moving the first injector to a location proximal the third yarn storage container, propelling a second length of the first yarn into the third yarn storage container.

19. The creeling system of claim 18, wherein the yarn storage system comprises a transporting system.

20. The creeling system of claim 19, wherein the first length of the first yarn propelled into the first yarn storage container is between 2,000 and 10,000 feet (between 609.6 and 3,048 meters).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. This description is given for the sake of example only, without limiting the scope of the invention. The reference figures quoted below refer to the attached drawings, wherein:

(2) FIG. 1A to 1D are schematic views of tubular containers from a yarn storage system according to the invention;

(3) FIG. 2A to 2F are schematic views of tubular containers from a yarn storage system according to the invention;

(4) FIGS. 3 and 4 are schematic views of yarn storage systems according to the invention;

(5) FIG. 5 schematically represents a method to store yarn in a yarn storage system according to the invention;

(6) FIG. 6 represents a textile production assembly in accordance with the tenth aspect of the invention;

(7) FIG. 7 provides a front view on the yarn storage system of FIG. 6 in accordance with arrow F7;

(8) FIG. 8 in a similar view represents a variant;

(9) FIG. 9 provides a perspective view on the support of FIG. 6 in accordance with arrow F9;

(10) FIG. 10 on a larger scale shows a cross-section according to the line X-X shown in FIG. 6;

(11) FIGS. 11 to 13 represent variants for the yarn storage system of FIG. 6 in a view on the area indicated with F10 in FIG. 6;

(12) FIG. 14 represent a view in accordance with the arrow F14 of FIG. 13;

(13) FIG. 15 represents a method for producing yarn in accordance with the thirteenth aspect of the invention; and

(14) FIG. 16 represents a creeling system in accordance with the fourteenth aspect of the invention.

(15) The same reference signs refer to the same, similar or analogous elements in the different figures.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

(16) The present invention will be described with respect to particular embodiments. It is to be noticed that the term comprising, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, steps or components as referred to, but does not preclude the presence or addition of one or more other features, steps or components, or groups thereof. Thus, the scope of the expression a device comprising means A and B should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

(17) Throughout this specification, reference to one embodiment or an embodiment are made. Such references indicate that a particular feature, described in relation to the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases in one embodiment or in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment, though they could.

(18) Furthermore, the particular features or characteristics may be combined in any suitable manner in one or more embodiments, as would be apparent to one of ordinary skill in the art.

(19) According to a first independent aspect of the invention, a yarn storage system is provided.

(20) A yarn storage system for storing multiple non-wound yarns will be described hereinafter by making use of the figures. In FIG. 1A, an example of a yarn storage container comprising a container 101 is shown. In the example the container 101 is tubular and cylindrical.

(21) More in particular, an axial cross section of such tubular container is provided. The tubular container 101 has an axial length L of 72 inch in the axial direction 111 and a first axial extremity 113 and a second axial extremity 115. Each tubular container is fit for holding one non-wound yarn 200 having a length at least double of the axial length of the tubular container. The first axial extremity 113 has an opening 123 for receiving an end of one of the non-wound yarns. The second axial extremity 115 of each of the tubular containers is air-permeably closed, e.g. by means of a polymer grid 125 being welded along the circumference of the second axial extremity 115.

(22) The tubular container 101 has a wall thickness T of inch, has a circular radial cross section and an inner diameter D of 2.78 inch.

(23) Notably, the ratio of the axial length L to the inner diameter D is larger than 10, and in this case even larger than 25.

(24) The tubular wall 501 comprises two sections, a first section 511 with length Le1 being 54 inch, and a second section 513 with length Le2 being 18 inch. In each of the sections, the tubular wall has apertures or openings 521 and 523. In section 511, the tubular wall has 4 rows of apertures 521 along its circumference, the rows equidistant one to the other along the circumference. Each row has 18 apertures 521 being circular apertures with diameter d1 of inch. The distance wall-to-wall w1 between the apertures in axial direction is 2.875 inch. The distance center to center between the apertures in axial direction is d1+w1 being 3 inch. This first section has an inner tube surface area of 487 inch.sup.2. The apertures 521 together provide 0.884 inch.sup.2 open surface. Hence the open areas expressed as % of the surface area of tubular wall in this section 511 is 0.18%.

(25) In section 513, the tubular wall has 6 rows of apertures 531 along its circumference, the rows equidistant one to the other along the circumference. Each row has 18 apertures or openings 531 being circular apertures with diameter d2 of inch. The distance wall-to-wall w2 between the apertures in axial direction is 0.875 inch. The distance center to center between the apertures or openings in axial direction is d2+w2 being 1 inch. This second section has an inner tube surface area of 163 inch.sup.2. The apertures 531 together provide 1.325 inch.sup.2 open surface. Hence the open areas expressed as % of the surface area of tubular wall in this section 531 is 0.82%.

(26) In total, the inner surface area of the tube is 650 inch.sup.2, and is provided with in total 2.209 inch.sup.2 open area by means of the apertures in the first and second section. The open areas expressed as % of the surface area of tubular wall in its totality is 0.34%.

(27) An alternative, also tubular, container 102 is shown in FIG. 1B. The tubular container 102 again has an axial length L of 72 inch in the axial direction 111 and a first axial extremity 113 and a second axial extremity 115. Each tubular container is fit for holding one non-wound yarn 200 having a length at least double of the axial length of the tubular container. The first axial extremity 113 has a cap 127 provided with an electrically conductive grommet 128 which on its term defines the opening 123 for receiving an end of one of the non-wound yarns. The second axial extremity 115 of each of the tubular containers is air-permeably closed, e.g. by means of a cap 126 being slid in the container 102 along the circumference of the second axial extremity 115.

(28) The grommet 128 is a copper grommet with a diameter of the opening of inch. Both caps 127 and 126 are made out of polymer. The cap 126 is air permeable as it is provided with a plurality of openings 129.

(29) The tubular container has a wall provided with apertures or openings identical to the wall set out in FIG. 1a.

(30) An alternative tubular container 103 is shown in FIG. 1C. The tubular container 103 again has an axial length L of 72 inch in the axial direction 111 and a first axial extremity 113 and a second axial extremity 115. Each tubular container is fit for holding one non-wound yarn 200 having a length at least double of the axial length of the tubular container. The first axial extremity 113 has a cap 130 provided with an electrically conductive tube 131 which on its term defines the opening 123 for receiving an end of one of the non-wound yarns. The cap has plurality of small openings 136 along the contact zone where the cap 130 contacts the first axial extremity 113. The second axial extremity 115 of each of the tubular containers is air-permeably closed, e.g. by means of a cap 137 being slid on the container 104 along the circumference of the second axial extremity 115.

(31) To the outer end of the cap 137, a vacuum system 140 is mounted to create a minor lower air pressure in the tubular container 103. Via the openings 136, air is sucked into the tubular container 103 and creates a laminar flow in the tubular container 103 at least along the walls 109 of the tubular containers.

(32) Caps 130 and 137 are made out of polymer. The cap 137 is air permeable as it is provided with a plurality of openings 129.

(33) The tubular container has a wall provided with apertures or openings identical to the wall set out in FIG. 1a.

(34) Still another alternative tubular container 104 is shown in FIG. 1D. The tubular container 104 again has an axial length L of 72 inch in the axial direction 111 and a first axial extremity 113 and a second axial extremity 115. Each tubular container is fit for holding one non-wound yarn 200 having a length at least double of the axial length of the tubular container. The first axial extremity 113 has a cap 135 provided and, optionally, an electrically conductive, brush 150 which defines a circular opening between the bristles 151 of diameter db being inch. As such an opening 123 for receiving an end of one of the non-wound yarns is defined. The yarn end 200 may contact the bristles 151. The second axial extremity 115 of each of the tubular containers is air-permeably closed, e.g. by means of a cap 132 being slid on the container 103 along the circumference of the second axial extremity 115. The second axial extremity 115 of each of the tubular containers is air-permeably closed, e.g. by means of a cap 137 being slid on the container 104 along the circumference of the second axial extremity 115.

(35) Caps 132 and 135 are made out of polymer. The cap 132 is air permeable as it is provided with a plurality of openings 129.

(36) The tubular container has a wall provided with apertures or openings identical to the wall set out in FIG. 1a.

(37) In the alternative, the tubular containers of FIGS. 1A to 1D may have another radial cross section, e.g. rectangular, square or oval. The dimensions of these cross sections may be chosen such that the overall cross sectional surface is about equal to the ones as shown in the FIGS. 1A to 1D.

(38) The grommets 128, the tubes 131 and/or the circumference of the first axial extremity 113 may be electrically conductive and may be grounded.

(39) Optionally the inner wall 109 may be provided with an electrically conductive layer or strips, which on their turn may also be grounded.

(40) The tubular containers of FIGS. 1A to 1D comprise a tubular wall made from transparent polystyrene.

(41) In FIGS. 2a to 2f, several suitable tubular walls 601 to 606, fit for being used as part of the tubular container are shown schematically. In FIGS. 2a to 2e, the tubular wall has two sections 611 and 613.

(42) In FIG. 2a, the first section 611 comprises 8 rows of circular openings 622, all on a given center to center distance d one to the other in axial direction. In the other section 613, closer to the second axial extremity 663, the section comprises 8 rows of circular openings 622, all on a center to center distance being only d/2 one to the other in axial direction. Therefore, the total open area per surface unit in section 613 is double the total open area per surface unit in section 611.

(43) In FIG. 2b, the first section 611 comprises 4 rows of circular openings 623, all on a given center to center distance d one to the other in axial direction. In the other section 613, closer to the second axial extremity 663, the section comprises 8 rows of identical circular openings 623, all on a center to center distance d one to the other in axial direction. Therefore, the total open area per surface unit in section 613 is double the total open area per surface unit in section 611.

(44) In FIG. 2c, the section 611 comprises 4 rows of capsule shape like openings 624, all on a given center to center distance d one to the other in axial direction. In the other section 613, closer to the axial extremity 663, the section comprises 4 rows of n identical capsule shape like openings 624, all on a center to center distance d/2 one to the other in axial direction. The section 613 further comprises 4 additional rows intermediately positioned between the other rows. Each of these intermediate rows comprise n1 identical capsule shape like openings 624, with additionally two further openings 625 having a circular shape with surface half of the surface of the capsule shape like openings 624. All openings 624 have their vertical walls parallel with the axial direction of the tubular container.

(45) Therefore, the total open area per surface unit in section 613 is double the total open area per surface unit in section 611.

(46) In FIG. 2d, the section 611 comprises 4 rows of capsule like openings 626, all on a given center to center distance d one to the other in axial direction. In the other section 613, closer to the axial extremity 663, the section comprises 4 rows of capsule like openings 626, all on a center to center distance being only d/4 one to the other in axial direction. Therefore, the total open area per surface unit in section 613 is quadruple the total open area per surface unit in section 611.

(47) In FIG. 2e, the section 611 comprises 4 rows of circular openings 627, all on a given center to center distance d one to the other in axial direction. In the other section 613, closer to the axial extremities 663, the sections comprise 4 rows of circular openings 626, all on a center to center distance being d one to the other in axial direction. The radius of the circular openings 628 is double the radius of the circular openings 627. Therefore, the total open area per surface unit in section 613 is quadruple the total open area per surface unit in section 611.

(48) For all embodiments in FIGS. 2a to 2e, the amount of open area per surface unit of tubular wall increase stepwise (with at least one step) along the axial length of the tubular container.

(49) In FIG. 2f, the tubular wall has no sections but is provided along its length with four rows of openings 629, all being identical and circular shaped.

(50) Consecutive openings in a row are on a given center to center distance d one to the other in axial direction. From the first axial extremity 662 towards the second axial extremity 663, the interdistance d between adjacent openings 629 decrease gradually.

(51) As such the amount of open area per surface unit of tubular wall increases from first axial extremity 662 towards the second axial extremity 663. Hence the amount of open area per surface unit of tubular wall increase gradually along the axial length of the tubular container.

(52) The skilled person understands that the various measures taken to locally modify the amount of open area per surface unit of tubular wall as applied in FIGS. 2a to 2f may be combined to vary this open area per surface unit of tubular wall.

(53) As shown in FIG. 3, a plurality of such tubular containers 1001 are matrix-wise mounted in a rack 1002 to form a yarn storage system 1000. The rack 1002 is moveably as it is provided with a set of wheels 1004. All tubular containers 1001 are identical, hence have the same length. Tubular containers of which the axial cross sections are shown in FIGS. 1A to 1D can be used.

(54) Using the tubes as shown in FIGS. 1A to 1D, 36 tubular containers 1001 are mount with the first axial extremities 113 being coplanar in vertical plane 1120. The tubular containers 1001 are mount in horizontal position. They are mounted matrix-wise with 6 rows of 6 tubular containers per row. In an alternative version, 9 rows of 18 tubes are mounted in a rack. Between adjacent containers, a distance of inch is respected. The tubes can be carried by at least two parallel plates provided with a hole, one for each tube. To hold the tubes in place, the tubes are mount in and supported by at least two parallel plates which are provided with openings, each opening to receive one tube. The openings in the plates have a diameter substantially equal to the outer diameter of the tubes. The distance center-to-center between two such openings is equal to the diameter of the tube plus inch. The first plate supports the tubes near the first axial extremities, the second plate supports the tubes near the second axial extremities.

(55) In front of the side 1100 providing the openings 123 of the tubular containers 1001, a yarn end holding means being a comb-like beam 1005 is provided which comprises at least as much seats as there are tubular containers in the rack 1002. The yarns 200, e.g. BCF yarns, for each of the tubular containers, are guided to one of the seats in the beam 1005. Such yarn end holding means 1005 is also referred to as comb-spacer or detacheable header. The yarn end holding means can be detached from the rest of the yarn storage system 1000.

(56) An alternative setup of a yarn storage system 2000 is shown in FIG. 4. The same reference signs refer to the same or similar items. The first axial extremities 113 of the tubular containers 1001 are now coplanar according to a horizontal plane 1110. At the lower side of the rack, a vacuum box 1009 is provided, with which the air permeable second axial extremities are in fluidal connection, i.e. when a vacuum is applied to the box 1009, e.g. by pump 1008, there will be air sucked from each of the second axial extremities, thereby creating a small under-pressure in the inner volume of the tubular containers 1001.

(57) For FIGS. 3 and 4, each of the yarn ends from the yarns 200, extending from the beam 1005, may be coupled to one on one to a needle of a tufting machine (not shown). During providing of the greige by the tufting machine, the yarns are taken substantially tension-less from the tubular containers, and are used as pile yarn in the greige. A greige with a given relatively short length (the length which can be made with the length of pile yarns residing in the tubular containers) of greige can be made. Once finished, a new yarn storage system replaces the emptied one, is coupled to the tufting machine and a new, potentially short run of a potentially different greige can be made. The advantage is that relatively short runs of greige can be provided, while no yarn creel with for each needle a yarn cone, is to be kept at hand.

(58) A system to execute method to store yarn is schematically shown in FIG. 5.

(59) A yarn storage system 5100 is provided. Examples of such system may be the ones shown in FIG. 3 or 4. The tubular containers of this yarn storage system 5100 are named 50XY, where X is an integer varying from 1 to N and Y an integer varying from 1 to M, N being the number of rows in the rack, M being the number of columns in the rack.

(60) A robot 5110 comprises a memory unit 5111 memorizing filling data, being for each tubular container its position (X and Y), the yarn (in this case yarn A, B or C) to be selected and the length of yarn to be injected and optionally, then the yarn storage system comprises a yarn end holding means, like a beam, the position of the opening in the yarn end holding means.

(61) The robot comprises an input means 5112 for inputting the filling data in the memory unit. This input means may be a keyboard to manually put in the data, or a data reading device reading the data from a data carrier (such as a floppy disk, a USB key or any other similar data storage medium), or may even by just an input port for coupling the memory unit to a computer or the web.

(62) The robot comprising a control unit 5113 defining the filling sequence of the tubular containers 50XY and controlling the injection of the selected yarn by means of hardware 5114 in the tubular containers while executing the filling sequence.

(63) In this embodiment, three yarn spools each comprising a BCF yarn (A, B and C) are stored in a rack 5100. Though also only one or two yarns may be used, possibly more than 3 yarns are provided such as 4, 5, 6, 7, 8, 9, 10 or more.

(64) During filling, the control unit will select one tubular container 50XY one after the other and reading out the filling data. In some embodiments, multiple tubular containers 50XY are filled by multiple injectors. The 3D moveable arm 5024 of the hardware 5014, will pick up the end of the selected yarn from the rack 5100 by its air blowing injector 5125. This injector may comprise a vortex injector 5126 which is fed with compressed air from storage 5127 via valve 5128. The injector will be brought in front of the opening 123 of the selected tubular container, and will blow the defined length of yarn into the tubular container via opening 123 using compressed air as fluid.

(65) Once this length is blown in, the injector may be moved in front of the corresponding opening 1006 of the beam 5005, and blows an end of yarn through the opening 1006. The yarn will be a double yarn going through the opening. The yarn is cut and either the same yarn is brought in front of the next selected tubular container, or is brought back to the rack 5100, while the injector 5125 selects another yarn to be used to fill the next tubular container.

(66) This sequence of actions is repeated until all necessary tubular containers are filled.

(67) As such, numerous tubular containers may be filled with a given length of yarn, while only a limited number of yarns on a limited number of spools being available.

(68) In another embodiment, multiple yarn storage systems, such as the yarn storage system 5100 of FIG. 5 are provided. A system with multiple sets of air blowing injectors 5125 feeding multiple sets of yarn storage containers 50XY is illustrated in FIG. 16.

(69) It is noted that the yarn end holding means 1005, represented in FIGS. 3 and 4, may comprise means for connecting yarns and/or yarn detectors. Such means for connecting yarns and/or yarn detectors may also be provided separately from the yarn end holding means 1005.

(70) FIG. 6 represents a textile production assembly 2000. The textile production assembly 2000 comprises a yarn storage system 1000 and a textile producing machine 2001. In this case, the textile production machine 2001 produces textile on the basis of continuous yarn 200 and is a tufting machine wherein said yarn 200 is used to form the pile 2002 of a tufted carpet. As schematically illustrated the tufting machine comprises needles 2003 that plant the pile yarn in to a backing material 2004. In this case, the backing material 2004 is provided from a roll 2005 and may concern a woven or non-woven textile, e.g. a glass fiber layer or a PET fiber layer. As illustrated the planted pile yarn is cut by means of a not represented cutting equipment active below the needles 2003. A greige 2006, it is a tufted backing, leaves the tufting machine, in this case, with its face 2007, i.e. the surface facing the room in use of the carpet, being turned downward. Clearly such greige 2006 may be further finished into a carpet product for example at least by fixing the pile 2002 at the bottom of the greige, here turned upward. The fixing may for example be executed by applying a second backing and/or by applying a latex or coPET containing material.

(71) The yarn storage system 1000 comprises several yarn storage containers 101 that each store an amount of continuous yarn 200, preferably a yarn 200 formed from bulked continuous carpet filament. The yarn 200 is drawn from the first axial extremity 113 of the containers 101. As is illustrated in FIG. 7, the containers 101 are tubular and cylindrical, wherein the first axial extremity 113 comprises a cap 127 with an opening 123 that receives the end of the yarn 200. FIG. 8 shows a variant wherein the containers 101 are hexagonal and also comprise a cap 127 with an opening 123 that receives the end of the yarn 200.

(72) The yarn storage containers 101, as illustrated in FIGS. 7 and 8, are stacked in a matrix, wherein said matrix is substantially uniform. With a uniform matrix it is meant that the axes of the respective containers 101 are positioned equidistantly from each other in a horizontal direction H and/or in a vertical direction V. In this case, the matrix formed by the yarn storage containers 101 of FIGS. 7 and 8 is uniform in both directions, wherein the distance D1 between the containers 101 in horizontal direction H is equal to the distance D2 between the containers 101 in vertical direction V in the case of FIG. 7, while the distance D1 and D2 are different in case of FIG. 8.

(73) FIGS. 7 and 8 further illustrate that at least a part of the outer wall 2008 of the containers 101 is free from contact with any of a plurality of adjacent containers 101. The matrix or stack of containers 101 comprised in said yarn storage system 1000 comprises voids 2009 substantially defined by the outer wall portions of a plurality of containers 101.

(74) In the case of the yarn storage system 1000 of FIG. 6, the containers 101 are positioned, in said storage system 1000 with their axial, i.e. length, direction 111 directed in a horizontal plane.

(75) The yarn storage system 1000 further comprises means 2010 for communicating with said textile producing machine or tufting machine 2001. As illustrated, amongst others in FIG. 6, the yarn storage system 1000 comprises a data storage 2011, and said means 2010 for communicating may transfer data from this data storage 2011 to said textile producing machine or tufting machine 2001.

(76) Further, in this case, the yarn storage system 1000 comprises means 2012 for detecting the yarn of the containers, i.e. yarn detectors, wherein the yarn detectors 2012 create a signal directly communicated to said textile machine through said means 2010 for communicating. Said means 2010 for communicating may be wired electronic connections between the yarn storage system 1000 and the textile production machine or tufting machine 2001.

(77) The illustrated textile production assembly 2000 comprises a yarn end holding means, in the form of a comb-like beam 1005. As illustrated in FIG. 9, the yarn end holding means comprises a number of slots 2013, said number of slots 2013 being identical or more than the number of containers 101 of the yarn storage system 1000, each slot 2013 being fit to receive one yarn end from one of the containers 101. The slots 2013 are all adjacent one next to the other in a row.

(78) In this case, the yarn end holding means is provided as a beam 1005 of metal in which the slots 2013 are provided. The yarn end holding means has a comb-like structure. In this case, the yarn end holding means comprises a set of teeth 2014 or protrusions for spacing individual yarns 200.

(79) The yarn end holding means forms a support for positioning the yarns 200 of said yarn storage system 1000. In dashed line 2015 a continuous yarn 200 is illustrated being fed to the textile production machine over the support. In dashed line 2016 it is illustrated that two yarn ends can be positioned in a slot 2013. This is advantageous for connecting the said yarn ends. In the represented example the two yarn ends are presented end-to-end. This is not necessarily the case. According to variants, the two yarn ends may be presented alongside each other or on top of each other on said support, preferably in a common slot 2013, preferably with their respective ends pointing in opposite directions.

(80) FIG. 10 illustrates that a heating and/or pressing element 2017 may be put in contact with the yarn ends to be connected. The heating and/or pressing element 2017 together with the support form a connection means 2018, more particularly a welding equipment, for connecting said yarns 200 while being positioned on said support. Preferably, these connecting means 2018 are used for connecting one or more yarns 200 of a first yarn storage system 1000 to one or more yarns 200 of a second, preferably similar yarn storage system 1000. By using such a welding equipment a fluent change-over from one yarn storage system 1000 to another can be attained, and the tufting machine 2001 may fluently change-over from a first design to a second design, wherein the one yarn storage system 1000 comprises at least the required yarn 200 for said first design and the second yarn storage system 1000 comprises at least the required yarn 200 for said second design. In this way a method for producing textile in accordance with the twelfth aspect can be obtained.

(81) FIG. 6 illustrates that textile production assembly 2000 may alternatively, or in combination with the yarn end detectors 2012 positioned proximate the yarn storage system 1000, be provided with one or more yarn detectors 2019 positioned further downstream, preferably downstream of said support or yarn end holder. Clearly such yarn detectors 2019 may also communicate through said communicating means 2010 with said textile production machine or tufting machine 2001.

(82) FIGS. 11 and 12 show a yarn storage system 1000 where the containers 101 are positioned, or are postionable, in said storage system 1000 with their axial direction 111 directed slopingly with respect to said horizontal plane, said slope being at an angle G of 15 or less with said horizontal plane. In this case the containers 101 are directed with their first axial extremity 113 being directed downwardly. In the case of FIG. 11 the containers 101 are slopingly mounted in the yarn storage system 1000, while in the case of FIG. 12 the containers 101 are e.g. horizontally mounted in the yarn storage system 1000, but the yarn storage system 1000 can be tilted, for example by lifting the side 2020 of the yarn storage system 1000 proximate the second axial extremity 115 of the containers 101, as indicated by means of the arrow 2021.

(83) FIGS. 13 and 14 illustrate that, alternatively to the yarn end holding means of FIG. 9, or in combination therewith, a yarn end holding means may be provided that comprises a number of apertures 2022, for example formed as a plate 2023 with through bore holes, preferably organized in two or more rows, here arranged in a matrix. In accordance with a not represented embodiment the apertures 2022 may be arranged in a zig-zag setup. Each aperture 2022 is provided with a ceramic tube 2024 to prevent the passing yarn 200 to wear out the aperture 2022. Preferably the yarns 200 pass through said aperture 2022 in the a matrix arrangement that corresponds to the matrix arrangement or the respective containers 101 in the yarn storage system 1001. Preferably therefore the apertures 2022 are provided at distances da-db in the horizontal direction H and/or vertical direction V equal to, or corresponding to the distances D1 and/or D2 defined by the matrix of the containers 101. In the case of a corresponding distance, not being equal, the distance d1-d2 can be uniformly scaled down or up from the distances D1 and/or D2, for example, the distances da-db may each be scaled down to half of the distance D1-D2 respectively.

(84) FIG. 15 illustrates a few steps in a method for producing yarn 200 suitable for feeding a tufting machine 2001. The method comprises the step S0 of melting and extruding a polymer, such as PET or PTT or PA, in this case using an extruder 2025 with one or more rotating screws. The method further comprises the step S1 of spinning the polymer melt into a plurality of filaments 2026. In this case several spinning stations 2027 are fed by the same polymer melt. Each spinning stations 2027 delivers the filaments 2026 for a yarn 200. The method further comprises the step S2 of converting said plurality of filaments 2026 to yarns 200. The conversion may comprise twisting and/or entangling of the filaments 2026. After the conversion the yarns 200 are directly injected into a yarn storage container 101, in this case comprised in a yarn storage system 1000. For the injection pressurized air can be used to propel the yarns 200, for example using vortex injectors 2028. The wholly or partially filled yarn storage system 1000 can then be used for feeding a tufting machine 2001, for example as in FIG. 6 by drawing yarn from the respective containers 101.

(85) FIG. 16 illustrates a creeling system 2029. The creeling system 2029 is configured to receive a plurality of yarn storage systems 1000, in this case four. The creeling system 2029 further comprises several sets of a plurality of injectors 2028 for injecting yarn 200 into the plurality of yarn storage containers 101 comprised in each of the yarn storage systems 1000. Preferably each injector 2028 injects a single type of yarn 200, i.e. yarn from the same color, type, quality and material, into the containers 101 of a particular yarn storage system 1000. As illustrated here, each injector 2028 is able to inject yarn 200 in a plurality of columns of the rack 1002 or stack of containers 101, as the sets of injectors 2028 are configured to move, in this case commonly, horizontally, preferably at least over a distance equal to twice, and preferably at least four times, the horizontal distance D1 between the yarn storage containers 101. Each injector 2028 is, in this case, also able to inject yarn 200 in a plurality of rows of the stack of containers 101, as the injectors 2028 are configured to move, in this case individually, vertically, preferably at least over a distance equal to four times the vertical distance D2 between the yarn storage containers 101. In this case, the injectors are configured to move at least such a distance that they can inject yarn in all containers of a particular row.

(86) The creeling system 2029 may further comprise a memory configured to or comprising the necessary data to direct the at least one set of injectors 2028 for injection of the required length of yarn 200 in each of the yarn storage containers.

(87) It is to be understood that although preferred embodiments and/or materials have been discussed for providing embodiments according to the present invention, various modifications or changes may be made without departing from the scope and spirit of this invention.