Description:A LAMINATING DEVICE INTEGRATED WITHIN A CIRCULAR WEAVING LOOM MACHINE
TECHNICAL FIELD
[0001] The present disclosure relates to the field of circular weaving loom machine and, more particularly, to a laminating device for a circular weaving loom machine to laminate an inner layer of a tubular liner to an outer layer of tubular woven fabric.
BACKGROUND
[0002] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
[0003] Inside-laminated tubular woven fabric is widely used to make tubular woven sacks that are versatile and used across multiple industries due to their durability, lightweight nature, and ability to provide enhanced protection to the contents. The lamination on the inner surface of the tubular woven fabric adds specific functional properties, making them ideal for various applications where moisture resistance, contamination prevention, and structural integrity are critical. The inside-laminated tubular woven sacks are used in storing grains, animal feed, food such as rice and salt, fertilizers, chemical powders and granules, cement bags, sand and aggregates, powdered materials such as gypsum, lime, and silica, polymer granules, plastic resins, pharmaceutical products, and hygiene products.
[0004] At present, the inside-laminated tubular woven fabric is laminated separately after the weaving of the tubular woven fabric is completed. Further, in the traditional process, the tubular woven fabric is laminated on an outside surface and after the tubular woven fabric is laminated and converted into bags or sacks, each laminated tubular woven fabric bag is manually inverted to position the laminated layer on the inner side.
[0005] But, this requires additional machinery, operational steps, and handling that increase production time and manufacturing costs. Further, the transporting of the tubular woven fabric to the separate lamination section introduces delays, logistical inefficiencies, and the risk of damage during handling. Sometimes, this leads to inconsistent laminated tubular woven fabric bag production.
[0006] Additionally, the need to shift tubular woven fabric between weaving, lamination, and finishing stations creates bottlenecks and delays in the production line. Thus, the traditional systems require separate spaces and equipment for weaving, lamination, and finishing, demanding significant factory floor space, manual intervention, and capital investment.
[0007] Further, to automate the manual reversal after lamination, there exist some devices that are used to make laminated tubular woven fabric. But, in such devices, the pre-laminated fabric roll is loaded onto the machine and the lamination is applied to the outer surface of the tubular woven fabric. Further, the machine pulls a set length of the laminated fabric and gathers it at one end. This gathering action effectively folds the tubular fabric inward, reversing the tubular fabric, and positioning the laminated layer on the inner surface. The gathered fabric is then reversed through a mechanical flipping process. This automation aims to eliminate the manual reversal step required in traditional workflows. But, in these machines, during the gathering stage, the tubular woven fabric is compressed and crushed, leading to creases, wrinkles, and damage to the lamination layer.
[0008] Therefore, there is a need for an inside lamination device that integrates process of lamination with the process of weaving to reduce the production time, labour, and associated costs. Further, there is a need for a device to laminate an inner surface of the woven fabric during the weaving process, eliminating the need for inverting the tubular woven fabric after lamination.
[0009] Additionally, there is a need for a device that combines the weaving and lamination steps into a single, synchronized process and ensures precise alignment of the tubular film with the woven tubular fabric as both are processed simultaneously.
OBJECTIVES
[0010] The prime objective of the present disclosure is to provide a circular weaving loom machine that may laminate an inner layer of tubular liner within the outer layer of tubular woven fabric.
[0011] Another objective of the present disclosure is to provide a laminating device within the circular weaving loom machine that may laminate an inner layer of tubular liner directly within the outer layer of tubular woven fabric, without the need for reversing the laminated woven tubular fabric.
[0012] Yet another objective of the present disclosure is to provide a laminating device within the circular weaving loom machine that aligns the inner layer of the tubular liner with the outer layer of the tubular woven fabric without damaging the inner layer or the outer layer.
[0013] Yet another objective of the present disclosure is to provide a laminating device within the circular weaving loom machine that laminates the inner layer of the tubular liner with the outer layer of the tubular woven fabric with a controlled heating temperature, to eliminate the burning of the inner layer or the outer layer during the lamination process.
[0014] Yet another objective of the present disclosure is to provide a lamination device to eliminate the need for fabric reversal after lamination, thereby suppressing additional manual handling and effectively increasing the efficiency.
[0015] Yet another objective of the present disclosure is to provide a circular weaving device to integrate lamination and weaving process together in order to offer a continuous production workflow and eliminate the aforementioned bottlenecks, thereby increasing the output.
[0016] Yet another objective of the present disclosure is to provide a lamination device that may maintain tight control over the lamination process, and ensure the final product with improved durability and performance.

SUMMARY
[0017] Before the present system and its components are described, it is to be understood that this disclosure is not limited to the particular system and its arrangement as described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the summary is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope of the present application. This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in detecting or limiting the scope of the claimed subject matter.
[0018] The present disclosure relates to a circular weaving loom machine. The circular weaving loom machine may be configured to receive an inner layer and nest it within an outer layer produced by the circular weaving loom machine.
[0019] The circular weaving loom machine may comprise a circular weaving unit configured to form an outer layer, wherein the outer layer may have a tubular shape. Further, the circular weaving loom machine may comprise an insertion unit configured under the circular weaving unit to insert an inner layer into the formed outer layer to form nested tubular layers.
[0020] According to an aspect of the present disclosure, the outer layer may be a layer of a tubular woven fabric. Further, the inner layer may be a layer of a tubular liner. Further, the tubular liner may be a tubular plastic film.
[0021] The circular weaving loom machine may further comprise a laminating device configured to laminate the nested tubular layers comprising the inner layer and the outer layer. The laminating device may comprise an expansion unit and a laminating chamber.
[0022] The expansion unit may be configured to receive the inner layer and the outer layer from the respective insertion unit and circular weaving unit the wherein the inner layer may be loosely nested within the outer layer. Further, the expansion unit may inflate the nested tubular layers to radially expand and align the inner layer with the outer layer. The expansion unit may further comprise a first nip, and a second nip distantly configured to the first nip. The second nip may be adjustable to enable a transition between a released position and a pinching position.
[0023] An actuation mechanism may be configured to adjust the second nip to enable the transition of the second nip between a released position and a pinching position. The actuation mechanism may be a mechanical actuator, a hydraulic actuator, a pneumatic actuator, or an electronic actuator.
[0024] The second nip may be configured to permit air to enter air within the nested tubular layers between the first nip and the second nip, from the nested tubular layers across the second nip in a released position. Further, the second nip may be configured to pinch the nested tubular layers to trap the entered air to inflate the nested tubular layers in a pinching position.
[0025] The expansion unit may further be configured to pinch the nested tubular layers between the first nip and the distant second nip to trap air within the pinched nested tubular layers and inflate the nested tubular layers.
[0026] According to an embodiment, the laminating chamber may be configured to heat the aligned nested tubular layers to laminate the inner layer to the outer layer. The laminating chamber may comprise a wall defining a hollow chamber. Further, one or more heaters may be mounted on the inner surface of the wall. The laminating chamber may be configured to receive the aligned nested tubular layers fed from the expansion unit into the hollow chamber and heat the aligned nested tubular layers to laminate the inner layer to the outer layer.
[0027] Further, one or more rollers may be configured at the side of the laminating chamber opposite to a side of the second nip, configured to receive the aligned nested tubular layers from the second nip through the laminating chamber to laminate the inner layer and the outer layer. Further, the aligned nested tubular layers may be inflated between the second nip and the one or more rollers to touch the one or more heaters for lamination. The one or more heaters may be at least one of ceramic heaters, mica heaters, ceramic mica heaters, or any other type of heaters.
[0028] The laminating device may further comprise a proximity sensor configured at a lower end of the hollow chamber to detect a diameter or a width of the nested tubular layers. The laminating device may further comprise a control unit which may be configured to receive data from the temperature sensor and control operations of the one or more heaters based on the data received from the temperature sensor, wherein the operations of the one or more heaters may be controlled to maintain a preset level of temperature within the laminating chamber.
BRIEF DESCRIPTION OF DRAWINGS
[0029] The embodiments of the disclosure itself, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 illustrates a view of a circular weaving loom machine, as an illustrative configuration of the present disclosure.
FIG. 2a illustrates a detailed view of an unwinder unit of the circular weaving loom machine, as an illustrative configuration of the present disclosure.
FIG. 2b illustrates a detailed side view of the unwinder unit of the circular weaving loom machine, as an illustrative configuration of the present disclosure.
FIG. 3 illustrates a cut sectional view of an insertion unit of the circular weaving loom machine, as an illustrative configuration of the present disclosure.
FIG. 4 illustrates a view of a spreader unit of the circular weaving loom machine, as an illustrative configuration of the present disclosure.
FIG. 5 illustrates a view of the laminating device of the circular weaving loom machine, as an illustrative configuration of the present disclosure.
FIG. 6 illustrates a view of an expansion unit of the laminating device, as an illustrative configuration of the present disclosure.
FIG. 7a illustrates a top view of a laminating chamber of the laminating device, as an illustrative configuration of the present disclosure.
FIG. 7b illustrates a cut sectional view of the laminating chamber of the laminating device, as an illustrative configuration of the present disclosure.
FIG. 8 is an electronic bock diagram of the circular weaving loom machine, according to an aspect of the present disclosure.
DETAILED DESCRIPTION
[0030] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[0031] Embodiments of the present invention include various steps, which will be described below. The steps may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the steps. Alternatively, steps may be performed by a combination of hardware and or by human operations.
[0032] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0033] As used in the description herein and throughout the claims that follow, the meaning of “a”, “an”, and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “on” unless the context clearly dictates otherwise.
[0034] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this invention will be thorough and complete and wilfully convey the scope of the invention to that ordinary skill in the art. Moreover, all the statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
[0035] While embodiments of the present invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the invention, as described in the claim.
[0036] Generally, circular weaving machines are used to produce a tubular woven fabric, which is commonly used to manufacture sacks and other packaging materials. To enhance the functional properties, such as moisture resistance, printability, and structural integrity, a polymer coating or film layer is applied to the tubular woven fabric. Traditionally, lamination is performed on an outer surface of the tubular woven fabric, which often requires the tube to be inverted after the lamination, as accessing and laminating an inner surface of the tubular woven fabric is challenging using the traditional methods.
[0037] The present disclosure discloses an inside laminating device for laminating the inner surface of the tubular woven fabric. According to one embodiment, the laminating device is configured to receive the outer layer and the inner layer nested within the outer layer. The inner layer may be loosely nested within the outer layer. The laminating device is further configured to expand the nested layers by inflating them. Further, the laminating device is configured to heat the expanded nested tubular layers to laminate the inner layer to the outer layer.
[0038] FIG. 1 illustrates a view 100 of a circular weaving loom machine 102, as an illustrative configuration of the present disclosure. Referring to FIG. 1, the circular weaving loom machine 102 comprises a plurality of bobbins 104 comprising thermoplastic tapes, such as polypropylene or high-density polyethylene, configured to be woven into an outer layer 112 of the tubular woven fabric, an unwinder unit 106 configured to provide an inner layer 114 of the tubular liner, a circular weaving loom 108 configured to weave the threads into the outer layer 112, an insertion unit 110 configured to loosely nest the inner layer 114 within the outer layer 112 to form nested tubular layers 120, an expansion unit 122 defined between a first nip 116 and a second nip 118, distantly configured to the first nip 116, configured to receive the loosely nested inner layer 114 within the outer layer 112 through a first nip 116 and form aligned nested tubular layers 120, a laminating chamber 124 configured to receive and laminate the aligned nested tubular layers to form laminated tubular layers 126, and a laminated tubular layer winder 128 to wind the laminated tubular layers 126.
[0039] The circular weaving loom machine 102 comprises the circular weaving loom 108 configured to weave the outer layer 112. According to an embodiment, the circular weaving loom 108 may receive a plurality of threads of the fabric or thermoplastic tape from the plurality of bobbins 104 and weave them into the tubular woven fabric to form the outer layer 112. In an embodiment, the woven fabric may be woven by weaving needles. In another embodiment, the woven fabric may be woven by shuttles.
[0040] In an embodiment, the thread of the fabric may be polypropylene (PP) threads to make polypropylene (PP) material outer layer 112. In another embodiment, the thread of the fabric may be polyester threads to make a polyester material outer layer 112. In yet another embodiment, the thread of the fabric may be jute threads to make jute material outer layer 112. In yet another embodiment, the threads of the fabric may be cotton threads to make cotton material outer layer 112. In yet another embodiment, the plurality of threads of the fabric may be polypropylene multifilament threads to make polypropylene multifilament material outer layer 112. It may be considered that the plurality of threads may not be limited to the aforementioned materials and can be made from any other suitable material.
[0041] The circular weaving loom machine 102 comprises the unwinder unit 106 configured to introduce the inner layer 114 to the outer layer 112 through the insertion unit 110 to form loosely nested tubular layers 120, which is explained in detail later in the description.
[0042] The loosely nested tubular layers 120 may be passed through the expansion unit 122 to form nested tubular layers 120. The expansion unit 122 may be defined between the first nip 116 and the second nip 118. The expansion unit 122 may be configured to expand the inner layer 114 with the help of the air and align the expanded inner layer 114 with the outer layer 112 to form aligned nested tubular layers 120. The detailed explanation of the first nip 116, the second nip 118, and the expansion unit 122, which is defined by the first nip 116 and the second nip 118, is explained in detail later in the description.
[0043] The aligned nested tubular layers 120 may further be advanced from the expansion unit 122 to the laminating chamber 124, wherein the inner layer 114 and the outer layer 112, forming the aligned nested tubular layers 120, may be laminated together to make laminated tubular layers 126. The detailed explanation of the laminating chamber 124 is explained in detail later in the description.
[0044] Further, the laminated tubular layers 126 may be wound on the winder unit 128. The winder unit 128 may comprise a shaft configured to receive an empty reel, which may further be configured to receive and wind the laminated tubular layers 126, to form a reel of the laminated tubular layers 126.
[0045] In an embodiment, the winder unit 128 may be connected with a motor configured to wind the laminated tubular layers 126.
[0046] FIG. 2a illustrates a detailed view 200a of the unwinder unit 106 of the circular weaving loom machine 102, as an illustrative configuration of the present disclosure. FIG. 2b illustrates a detailed side view 200b of the unwinder unit 106 of the circular weaving loom machine 102, as an illustrative configuration of the present disclosure.
[0047] Referring to FIG. 2a and 2b, the unwinder unit 106 is configured to receive a reel of the inner layer 112 and unwind the reel of the inner layer 112 to gradually introduce the inner layer 112 to the insertion unit 110. The unwinder unit 106 comprises the unwinder shaft 202 configured to support the reel of the inner layer 112, one or more braking bearings 204 configured to control the unwinder shaft 202, a brake lever 206 configured to control the one or more braking bearings 204, and a guiding roller 208 configured to guide the unwounded inner layer towards the insertion unit 110.
[0048] The reel of the inner layer 114 may be configured over the unwinder shaft 202, and may unwind the inner layer 114. In an embodiment, the unwinder shaft 202 may be driven by a motor to unwind the reel of the inner layer 114. In another embodiment, the inner layer 114 may be pulled by a pulling mechanism that may be configured at a suitable position in the circular weaving loom machine, which may cause it to unwind from the unwinder shaft 202. In another embodiment, the inner layer 114 may be pulled by any of the first nip 116, the second nip 118, or the winder unit 128.
[0049] In an embodiment, the inner layer 114 may be a layer of tubular liner. In another embodiment, the tubular liner may be a tubular plastic film, a polyethylene (PE) Film, a High-Density Polyethylene (HDPE) film, a laminated polypropylene (PP) film, a woven polypropylene (PP) film, a kraft paper PE film, or a biodegradable film. Further, the inner layer 114 may not be limited to the aforementioned materials and may be made from any other suitable material.
[0050] The unwinder shaft 202 may be supported by one or more braking bearings 204, hereinafter simply referred to as braking bearings 204. The braking bearings 204 may be configured to control the unwinding speed and maintain a constant tension of the unwinding inner layer 114. The braking bearings 204 may provide an opposite torque to the rotation of the unwinder shaft 202, and control the rotation of the unwinder shaft 202 to maintain a required speed and tension for unwinding the inner layer 114 at a constant rate and even tension. The uncontrolled unwinding the inner layer 114 may stretch, break or damage the inner layer 114 in any other way, which may cause improper lamination.
[0051] In an embodiment, the number of braking bearings 204 may be three braking bearings, that may be connected on the end of the unwinder shaft 202. In alternative embodiments, the number of braking bearings 204 may range from one bearing to six bearings.
[0052] The braking bearings 204 may be controlled manually through the brake lever 206. The brake lever 206 may be configured to manually control the braking bearings 204 to adjust the tension and speed of the unwinding reel of the inner layer 114 configured over the unwinder shaft 202.
[0053] In an alternative embodiment, the braking bearings 204 may be controlled automatically with the help of sensors and a control unit 802 (described later), wherein the sensors may detect the unwinding speed of the inner layer 114 and send the data to the control unit 802. The control unit 802 may further provide a signal to control the braking bearings 204 to adjust the tension and speed of the unwinding of the inner layer 114 configured over the unwinder shaft 202.
[0054] The unwinding inner layer 114 may further be guided towards the circular weaving loom 108, supported by at least one guiding roller 208. In various embodiments, the at least one guiding roller 208 may not be limited to a single roller and may range between a single roller and up to ten rollers, as per the requirement.
[0055] In an embodiment, the braking bearings 204 may be configured on any one end of the unwinder shaft 202. Further, the opposite end configured with the braking bearings 204 may be supported by free-moving bearings. In another embodiment, the braking bearings 204 may be configured on both ends of the unwinder shaft 202. In yet another embodiment, the free-moving bearings may be configured on both ends of the unwinder shaft 202, and a braking member may be configured over the unwinder shaft 202 to control the unwinding of the reel of the inner layer 114.
[0056] Further, the unwinder unit 106 may be supported by a base 210. The base 210 of the unwinder unit 106 may not be limited to any specific size and shape and may be any of the square, triangle, rectangle, semicircle, or any other shape. In a preferred embodiment, the base may be of a trapezoidal shape formed by a plurality of supporting angles or supporting rods. In an embodiment, the braking bearings 204 may be configured over the base through a supporting flange, wherein the braking bearings 204 may be connected to the supporting flange through threaded joints.
[0057] FIG. 3 illustrates a cut sectional view 300 of the insertion unit 110, as an illustrative configuration of the present disclosure. Referring to FIG. 3, the inner layer 114 may be received by the insertion unit 110 from the unwinder unit 106.
[0058] According to an aspect of the present disclosure, the insertion unit 110 may receive the inner layer 114 from the unwinder unit 106 through at least one guiding roller 302. The guiding roller 302 may be distantly configured to the bottom of the insertion unit 110, to guide the inner layer 114 to the insertion unit 110. In various embodiments, the guiding roller 302 may not be limited to a single roller and may range from a single roller up to ten rollers, as per the requirement.
[0059] The insertion unit 110 may comprise a bottom housing 304 configured to support the insertion of the inner layer 114 within the outer layer 112 woven by the circular weaving loom 108. The bottom housing 304 may comprise a bottom housing support member 306 configured near the bottom portion of the bottom housing 304, and a bottom housing support member 308 configured near the top portion of the bottom housing 304. Further, the insertion unit 110 may comprise a guiding pipe 310, configured within the insertion unit 110 to guide the passing of the inner layer 114 through the insertion unit 110.
[0060] In an embodiment, the insertion unit 110 may be directly configured below the circular weaving loom 108. In another embodiment, the insertion unit 110 may be connected to the circular weaving loom 108 through the bottom housing support members 306 and 308. In yet another embodiment, the insertion unit 110 may be supported by a base member configured over a steady surface.
[0061] FIG. 4 illustrates a side view 400 of a spreader unit 402, as an illustrative configuration of the present disclosure. Referring to FIG. 4, the circular weaving loom machine 102 comprises the spreader unit 402, configured over the insertion unit 110. The spreader unit may be configured over a top housing 404 of the insertion unit 110, as seen in FIG. 4.
[0062] According to an aspect of the present disclosure, the spreader unit 402 may comprise a plurality of outer layer guiding links 406, hereinafter simply referred to as guiding links 406. The guiding links 406 comprises a distal end and a proximal end, opposite to the distal end. The proximal end of the guiding link 406 may be connected to the top housing 404 of the insertion unit 110. In an embodiment, the guiding link 406 may be connected to horns 414 extending form the sides of upper portion of the top housing 404 of the insertion unit 110 as seen in FIG. 4. In an embodiment, the guiding links 406 may be connected to the horns 414 through pivot joints, wherein the guiding links 406 may pivot with respect to the of upper portion of the top housing 404 of the insertion unit 110 through the horns 414.
[0063] According to an embodiment, the distal end of the guiding link 406 may be freely suspended in an upward direction. Further, the distal end of the guiding links 406 may comprise at least one guiding roller 410, hereinafter simply referred to as guiding roller 410, connected to the upper part of the guiding link 406. In an embodiment, the guiding roller 410 may be directly connected to the guiding link 406. Further, the guiding roller 410 may be connected to the guiding link through connecting links 412 as seen in FIG. 4.
[0064] The guiding roller 410 may be configured to guide the outer layer 112 with even tension to prevent creases and damage to the outer layer 112. In an embodiment, the guiding roller 410 may be adjusted pivotally to adjust the amount of tension to be maintained on the outer layer 112 received from the circular weaving loom 108. Further, the guiding links 406 may be supported by supporting links 408 to enable a pivot movement of the guiding links 406 with extra support and to absorb the radial force exerted by the outer layer 112 on the guiding links 406 and prevent the guiding links 406 from collapsing inward. Furthermore, the multiple guiding links 406 and their corresponding supporting links 408 may be configured to pivot in a kinematic chain wherein a specific amount of motion in a single guiding link 406 and its corresponding supporting link 408 may create a similar amount of motion in all the other guiding links 406 and their corresponding supporting links 408.
[0065] In an embodiment, the two guiding links 406 to each other in the spreader unit 402. In another embodiment, more than two guiding links 406 may be configured equidistant to the adjacent guiding links 406 and positioned at equal angular intervals within the spreader unit. In yet another embodiment, the number of guiding links 406 may range from two guiding links 406 upto ten guiding links 406. Further, each of the guiding links 406 may comprise respective supporting links 408 and respective guiding rollers 410.
[0066] Further, as the outer layer 112 may pass through the outer surface of the spreader unit 402, the inner layer 114 may simultaneously pass through the center of the spreader unit, guided by the guiding pipe 310. In an embodiment, the inner layer 114 may be loosely nested within the outer layer 112, within the insertion unit 110, and the spreader unit 402.
[0067] FIG. 5 illustrates a view 500 of the laminating device 502 of the circular weaving loom machine 102, as an illustrative configuration of the present disclosure.
[0068] Referring to FIG. 5, the laminating device 502 comprises the expansion unit 122 and the laminating chamber 124. The expansion unit 122 may be defined between the first nip 116 and the second nip 118, distantly configured to the first nip 116, as seen in FIG. 5. The expansion unit 122 may be configured to pre-align the outer layer 112 with the loosely nested inner layer 114 before heating in the lamination chamber 124. The pre-alignment of the layers causes uniform lamination of the inner layer 114 on an inner surface of the outer layer 112.
[0069] The expansion unit 122 may be configured to pull and receive the nested tubular layers, including a loosely nested inner layer 114 within the outer layer 112, through the first nip 116. Further, during transmission between the first nip 116 and the second nip 118, the nested tubular layers may be pinched by the first nip 116 and the second nip 118. Further, the nested tubular layers may be inflated between the pinching positions to expand the nested tubular layers in a radially outward direction. This expansion causes the loosely nested inner layer 114 to uniformly align with the outer layer 112 to form aligned nested tubular layers 120 that discharge out of the second nip 118 and are fed to the laminating chamber 124 for further lamination. It is to be understood that the inner layer 114 is inflated using an air that causes inflation of the outer layer 112 in the radially outward direction.
[0070] According to an embodiment, the inner layer 114 may be inflated by trapping the air within the inner layer 114, between the pinching position (the first nip 116 and the second nip 118).
[0071] According to an embodiment, the second nip 118 may be adjustable to transition between a released position and a pinching position. The transition of the second nip 118 between the released position and the pinching position may be governed by the actuation mechanism 504, which will be explained in greater detail later in this document.
[0072] It is to be understood that the default position of the second nip 118 is pinching position. However, to inflate the tubular nested layers within the expansion unit 122, the second nip 118 may be moved to the released position from the pinching position. This shifting of the second nip 118 opens an end of the tubular nested layers, causing the air to enter. In an alternate embodiment, and air injection source (not shown) may be used to inject the air. The air injection source may be positioned between the first nip 116 and the second nip 118, within the expansion unit 122. Alternately, the air injection source may be positioned after the second nip 118 and inject the air. The injected air enters within the tubular nested layers that are present within the expansion unit 122 when the second nip 118 is shifted to the released position.
[0073] Once the air is injected or entered within the nested tubular layers that are present within the expansion unit 122 (between the first nip 116 and the second nip 118) and the tubular nested layers are inflated, the second nip is moved back to the default pinching position trapping the air within the nested tubular layers. Thereby, the trapped air continuously inflates the nested tubular layers during their travel between the first nip 116 to the second nip 118, causing the inner layer 114 and the outer layer 112 to continuously align with each other.
[0074] The aligned nested tubular layers 120 may further pass from the second nip 118 to the laminating chamber 124. The laminating chamber 124 is configured to laminate the inner layer 114 and the outer layer 112 of the aligned nested tubular layers 120 to form the laminated tubular layers 126.
[0075] FIG. 6 illustrates a detailed view 600 of an expansion unit 122 of the laminating device 502, as an illustrative configuration of the present disclosure. Referring to FIG. 6, the inner layer 114 and the outer layer 112 are pulled or received by the expansion unit 122 defined between the first nip 116 and the second nip 118, through the first nip 116. The expansion unit 122 is configured to inflate the inner layer 114 and the outer layer 112 and align the inner layer 114 and the outer layer 112 to form the aligned nested tubular layers 120. Further, the expansion unit 122 is configured to trap air between the first nip 116 and the second nip 118, wherein the nested tubular layers 120 may pass from the first nip, and inflate within the expansion unit 122 through the trapped air, and thereby align the inner layer 114 and the outer layer 112 of the nested tubular layers 120. The expansion unit 122 may be further configured to pass the aligned nested tubular layers 120 through the second nip 118 to the laminating chamber 124. The alignment of the inner layer 114 and the outer layer 112 may remove the creases and folds within the inner layer 114 and the outer layer 112, and prevent them from any damage during the lamination due to misalignment.
[0076] In an embodiment, the first nip 116 positioned above the spreader unit 402 may comprise a first roller 602 and a second roller 604 positioned beside the first roller 602. The first roller 602 and the second roller 604 may be positioned such that they are in constant contact with each other. Further, the loosely nested tubular layers 120 received from the spreader unit 402, comprising the inner layer 114 and the outer layer 112, may be configured to be squeezed and pinched through the contact point between the first roller 602 and the second roller 604 of the first nip 116. In an embodiment, the inner layer 114 and the outer layer 112 may be received by the right-hand side of the first roller 602, and guided through the top side of the first roller 602 towards the contact point between the first roller 602 and the second roller 604. The inner layer 114 and the outer layer 112 may be squeezed and pinched to form the nested tubular layers 120. Furthermore, the nested tubular layers 120 may be passed from the contact point between the first roller 602 and the second roller 604 and pass through the left-hand side of the second roller 604, through the bottom side of the second roller 604, towards the top side of the second roller 604 as shown in FIG. 6. The nested tubular layers 120 may further be inflated as they reach the top portion of the second roller 604 by the air trapped between the first nip 116 and the second nip 118.
[0077] In an embodiment, the contact point between the first roller 602 and the second roller 604 may be air-tight contact point that may prevent the passage of air beyond the contact point of the first roller 602 and the second roller 604.
[0078] In an embodiment, the number of rollers in the first nip may not be limited to two, and the first nip may comprise a third roller and a fourth roller to pull the loosely nested layers of the inner layer 114 and the outer layer 112.
[0079] The inflated nested tubular layers 120 may further pass from the first nip 116 towards the second nip 118. According to an aspect of the present disclosure, the nested tubular layers 120 may be guided towards the second nip 118 through one or more rollers (606a and 606b) configured between the first nip 116 and the second nip 118, positioned near the second nip 118.
[0080] In an embodiment, the second nip 118 may be configured within a housing 612. The rollers 606a may be configured on a first roller strip 608a, and similarly, the rollers 606b may be configured on a second roller strip 608b. Hereinafter, the one or more rollers (606a and 606b) may be collectively referred to as rollers 606.
[0081] In an embodiment, the number of rollers 606 on the respective first roller strip 608a and the second roller strip 608b may vary from one roller to fifty rollers, as per the requirement.
[0082] Further, the first roller strip 608a and the second roller strip 608b may be pivotally connected at separate pivot points adjacent to the second nip 118, within the housing 612. The distance between the pivot points of the first roller strip 608a and the second roller strip 608b may be adjusted in a manner that it may allow the passing of the nested tubular layers 120 through a gap between the pivoted ends of the first roller strip 608a and the second roller strip 608b, but trap the air and prevent the passage of the air between the pivoted ends of the first roller strip 608a and the second roller strip 608b. According to an embodiment, the nested tubular layer 120 may not be directly in contact with the first roller strip 608a and the second roller strip 608b, but rather be guided by the rollers 606 configured on the respective first roller strip 608a and the second roller strip 608b. The nested tubular layers 120 may pass through the gap between the first roller strip 608a and the second roller strip 608b, guided by the rollers 606, and may be introduced to the second nip 118.
[0083] In an embodiment, the angle between the first roller strip 608a and the second roller strip 608b may be varied according to the external diameter of the nested tubular layers 120. In an embodiment, the angular distance between the first roller strip 608a and the second roller strip 608b may be increased when passing the nested tubular layers 120 having a larger diameter. In another embodiment, the distance between the first roller strip and the second roller strip may be decreased when passing the nested tubular layers 120 having a smaller diameter.
[0084] In an embodiment, the angular distance between the first roller strip 608a and the second roller strip 608b may be adjusted by adjustment grooves (610a and 610b), hereinafter simply referred to as adjustment grooves 610, unless described otherwise. In an embodiment, the adjustment grooves 610 may be curved grooves to adjust the respective first roller strip 608a and the second roller strip 608b angularly with respect to their respective pivot points. In an embodiment, the adjustment grooves 610 may be provided on the housing 612. In an alternative embodiment, a single adjustment groove may be provided to adjust the angle between both the first roller strip 608a and the second roller strip 608b, instead of separate adjustment grooves (610a and 610b).
[0085] The first roller strip 608a and the second roller strip 608b may be fastened at a required angle with the respective adjustment grooves 610a and 610b. For instance, the first roller strip 608a may be fixed by fastening it to the required angular position on the first adjustment groove 610a at a required angle. Similarly, the second roller strip 608b may be fixed by fastening it to the required angular position on the second adjustment groove 610b at a required angle. Further, the angle between the first roller strip 608a and the second roller strip 608b may be adjusted by unfastening the first roller strip 608a and the second roller strip 608b with the respective adjustment grooves 610a and 610b, repositioning the first roller strip 608a and the second roller strip 608b at the required angle and fastening them back at the required repositioned angle.
[0086] In an embodiment, the first roller strip 608a and the second roller strip 608b may be configured with connecting links, wherein the connecting links may be configured such that an angular movement of either of the first roller strip 608a or the second roller strip. In another embodiment, the distance between the first roller strip 608a and the second roller strip 608b may be a fixed angular distance without any adjustment grooves.
[0087] The aligned nested tubular layers 120 may be guided by the rollers 606 towards the second nip 118.
[0088] The second nip 118 may comprise a first roller 614 and a second roller 616 positioned beside the first roller 614. The first roller 614 and the second roller 616 may be positioned such that they are in constant contact with each other. Further, the aligned nested tubular layers 120, received from the first nip 116 through the rollers 606 may be configured to be squeezed and pinched through the contact point between the first roller 614 and the second roller 616 of the second nip 118.
[0089] According to an embodiment, the aligned nested tubular layers 120 may be passed through the contact point of the first roller 614 and the second roller 616, and pass through the right-side of the second roller and expand by the air as shown in FIG. 6. Further, the aligned nested tubular layers 120 may be expanded by the air trapped between the second nip 118 and one or more rollers (714a and 714b).
[0090] According to an embodiment, the second nip 118 may be adjusted to transition between a released position and a pinching position.
[0091] According to an embodiment, an actuation mechanism 504 may be connected to the first roller 614 of the second nip 118, to transition the second nip 118 between the released position and the pinching position. The actuation mechanism 504 may be configured to move the first roller 614 linearly to increase or decrease the distance between the first roller 614 and the second roller 616. The increased distance between the first roller 614 and the second roller 616 may loosen the nested tubular layer 120 for the air to enter within the nested tubular layers 120, which may be referred to as a released position. Further, the decreased distance between the first roller 614 and the second roller 616 may pinch the aligned nested tubular layers 120, to allow only the aligned nested tubular layers 120 to pass between the first roller 614 and the second roller 616 and trap air between the first nip 116 and the second nip 118, that may be referred to as pinching position. The trapped air may cause a continuous inflation of the nested tubular layers 120 between the first nip 116 and the second nip 118. The inflation of the nested tubular layers 120 may enable the loosely nested inner layer 114 to radially expand and align with the outer layers 112.
[0092] In a case, the nested tubular layers 120 may have a hole or slit or any other deformity that may cause the trapped air to escape from the nested tubular layers 120. The escape of the trapped air may affect the inflation of the nested tubular layers 120 and may cause an improper expansion and alignment of the loosely nested inner layer 114 with the outer layer 112. Therefore, in such cases, the actuation mechanism 504 may shift the second nip 118 from the pinching position to the released position so that the air from the other side of the second nip may enter within the nested tubular layers 120 between the first nip 116 and the second nip 118. Further, the actuation mechanism 504 shifts back the second nip 118 to the pinching position, once sufficient amount of air is entered within the nested tubular layers 120. Accordingly, a sufficient amount of trapped air is maintained in the nested tubular layers 120 within the expansion unit 122 for uniform expansion of the loosely nested inner layer 112 within the outer layer 114.
[0093] In an embodiment, the actuation mechanism 504 may comprise a mechanical actuator to shift the position of the second nip 118. In another embodiment, the actuation mechanism 504 may comprise a hydraulic actuator, a pneumatic actuator, an electronic actuator, or any other suitable type of actuator.
[0094] In an embodiment, the expansion unit 122 may be configured with a sensor (not shown) to monitor the diameter of the nested tubular layers 120 when inflated, thereby monitoring the reduction in the quantity of air trapped between the nested tubular layers 120. In an embodiment, the sensor may be a proximity sensor. In another embodiment, the sensor may be any other suitable type of sensor configured to detect the reduction in quantity of the air trapped between the first nip 116 and the second nip 118. In an embodiment, the sensor may be configured near the first nip 116 or near the second nip 118. In another embodiment, the sensor may be configured at any position between the first nip 116 and the second nip 118.
[0095] In an embodiment, the sensor may be connected to the control unit 802, as shown in FIG. 8, and transmit the data corresponding to the amount of trapped air in the nested tubular layers 120 between the first nip 116 and the second nip 118. In response, the control unit 802 may generate a signal to control the actuation mechanism 504 to allow passage of air through the first roll 614 and the second roll 616 of the second nip 614 by changing the position of the second nip 118 from pinching position to the released position, and again from the released position to the pinching position once a sufficient amount of air is trapped between the first nip 116 and the second nip 118.
[0096] In another embodiment, the actuation mechanism 504 may be controlled manually to allow the passage of air through the first roll 614 and the second roll 616 of the second nip 614, upon detecting the reduction of the quantity of the air trapped between the first nip 116 and the second nip 118.
[0097] In one embodiment, the expansion unit 122 may be configured with an alarming device (not shown) that may be configured to provide an audible sound upon detecting a reduction in the quantity of air in the nested tubular layers 120 between the first nip 116 and the second nip 118.
[0098] Further, at least one of the first roller 602 and the second roller 604 of the first nip 116 may be connected with a motor (not shown) for their rotation. Similarly, at least one of the first roller 614 and the second roller 616 of the second nip 118 may be connected to a motor (not shown) for their rotation. In an embodiment, a single motor may be configured to rotate both the first roller 602 and the second roller 604 of the first nip 116. Similarly, another single motor may be configured to rotate both the first roller 614 and the second roller 616 of the second nip 118. In another embodiment, an individual motor may be provided for each of the first roller 602 and the second roller 604 of the first nip 116, and the first roller 614 and the second roller 616 of the second nip 118.
[0099] Further, the first roller 602 and the second roller 604 of the first nip 116, and the first roller 614 and the second roller 616 of the second nip 118 may be made from, but not limited to rubber compounds, high hardness elastomers, plastics, fiber-based rollers, metallic rollers, or a combination of any of the aforementioned rollers or any other suitable material.
[00100] Further, one or more rollers (618a and 618b) may be configured at the bottom of the second nip 118 to guide the aligned nested tubular layers 120 towards the laminating chamber 124. The rollers 618a may be configured on a first roller strip 620a, and similarly, the rollers 618b may be configured on a second roller strip 620b, as shown in FIG. 6. Hereinafter, the one or more rollers (618a and 618b) may be collectively referred to as rollers 618. The first roller strip 620a and the second roller strip 620b may be pivotally connected at separate distant points near the bottom of the second nip 118.
[00101] According to an embodiment, the aligned nested tubular layer 120 may not be directly in contact with the first roller strip 620a and the second roller strip 620b, but rather be guided by the rollers 618 configured on the respective first roller strip 608a and the second roller strip 608b, towards the laminating chamber 124.
[00102] In an embodiment, the angle between the first roller strip 608a and the second roller strip 608b may be varied according to the external diameter of the aligned nested tubular layers 120, and the internal diameter of the laminating chamber 124. In an embodiment, the angular distance between the first roller strip 608a and the second roller strip 608b may be increased or decreased to facilitate the passing of the aligned nested tubular layers.
[00103] FIG. 7a illustrates a top view 700a of a laminating chamber 124 of the laminating device 502, as an illustrative configuration of the present disclosure. FIG. 7b illustrates a cut sectional view 700b of the laminating chamber 124 of the laminating device 502, as an illustrative configuration of the present disclosure.
[00104] The laminating device 502 comprises a lamination chamber 124 positioned below the second nip 118 to receive the aligned nested tubular layers 120 from the second nip 118. Referring to FIG. 7a and FIG. 7b, the lamination chamber 124 comprises a wall 702 defining a hollow chamber 704 to receive the nested tubular layers 120, one or more heaters 706 mounted on an inner surface of the wall 702, clamps 708, a temperature sensor 710, a proximity sensor 712, one or more rollers 714a and 714b configured on respective first roller strip 716a and a second roller strip 716b, a first roller adjuster 718a and a second roller adjuster 718b, one or more supporting rollers 720, and a base 722.
[00105] The wall 702 may be made of a heat-proof or heat-resistant material to prevent dissipation of heat and damage to the tubular layers or other electronic components.
[00106] The hollow chamber 704 may be cylindrical in shape to accommodate the nested tubular layers 12 for uniform contact and lamination between the layers. In an alternate embodiment, the hollow chamber 704 may be a conical shape.
[00107] According to one embodiment, the temperature sensor 710 may be configured within the hollow chamber 704 to monitor the temperature within the hollow chamber 704. Further, the proximity sensor 712 may be configured at a lower end of the hollow chamber 704 to detect a diameter or a width of the nested tubular layers 120. Further, the rollers 714a and 714b are positioned below the hollow chamber 704 on respective first roller strip 716a and a second roller strip 716b and the first roller adjuster 718a and a second roller adjuster 718b configured to adjust the angle between the first roller strip 716a and the second roller strip 716b. Further, the supporting rollers 720 are configured to receive laminated tubular layers 126 from the laminating unit 124, and a base 722 is configured to support the laminating unit 124 and one or more supporting rollers 720.
[00108] Referring to the FIG. 7b, the aligned nested tubular layers 120 may be introduced to the hollow chamber 702 of the laminating device 124 from the second nip 118 guided by the rollers 618 configured over the respective first roller strip 620a and the second roller strip 620b.
[00109] Further, the aligned nested tubular layers 120 may be in an inflated condition between the first roller strip 620a and the second roller strip 620b, and the first roller strip 716a and the second roller strip 716b. The aligned nested tubular layers 120 may be inflated to enable the aligned nested tubular layers 120 to touch one or more heaters 706, which may laminate the inner layer 114 to the outer layer 112 by the high temperature of the one or more heaters 706 and form the laminated tubular layers 126. Hereinafter, the one or more heaters 706 may simply be referred to as heaters 706.
[00110] It is to be understood that the pinched aligned nested tubular layers 120 that are conveyed out of the second nip 118 is again inflated during the lamination process. The inflation may be similar to the inflation during expansion within the expansion unit 122. The air may be injected within the inner layer 114 of the tubular layers 120 using an injection source (not shown) or may be filled from an end of the tubular layers 120 before configuration of the tubular layers 120 through the one or more supporting rollers 720.
[00111] The supporting rollers 702 are configured on opposite side of the hollow chamber 704 from a side of the second nip 118. Further, the second nip 118 and the one or more supporting rollers 702 are configured as a pinching members to trap the air and inflate the tubular layers 120 during the lamination process within the lamination chamber 124. Further, the supporting rollers may be configured distantly from the hollow chamber 704 for uniform inflation of the tubular layers 120.
[00112] According to an embodiment, the heaters 706 may be mounted on an inner surface of the wall 702. In an embodiment, the heaters 706 may be ceramic heaters. In another embodiment, the heaters 706 may be mica heaters, ceramic-mica heaters, band heaters, flexible heating cables, flexible heating tables, flexible rubber heaters, flexible silicone heaters, or flexible silicone rubber heaters. In one embodiment, the heaters 706 may be cartridge heaters inserted between the outer wall and the hollow chamber. In one another embodiment, the heaters 706 may be heating coils wrapped around the hollow chamber 704. Further, the heaters 706 may be any other suitable type of heaters.
[00113] According to an aspect of the present disclosure, the heaters 706 may be configured to maintain a constant required temperature throughout the laminating process, the working of which will be explained in detail later in the specification.
[00114] The laminating device 124 may further comprise the temperature sensor 710 configured within the hollow chamber 704 to monitor the temperature within the hollow chamber 704. The temperature sensor 710 may be configured at any position within the hollow chamber 704. The laminating device 124 may further comprise the proximity sensor 712 configured at a lower end of the hollow chamber 704 to detect a diameter or a width of the aligned nested tubular layers 120. The working of the temperature sensor 710 and the proximity sensor 712 may be explained in detail later in the specification.
[00115] According to an aspect of the present disclosure, one or more rollers (714a and 714b) may be configured below the laminating chamber 124. The rollers 714a may be configured on a first roller strip 716a, and similarly, the rollers 714b may be configured on a second roller strip 716b. Hereinafter, the one or more rollers (714a and 714b) may be collectively referred to as rollers 714. In an embodiment, the number of rollers 714 on the respective first roller strip 716a and the second roller strip 716b may vary from one roller to fifty rollers, as per the requirement.
[00116] Further, the first roller strip 716a and the second roller strip 716b may be pivotally connected at separate pivoting points from their lower ends. Further, the laminated tubular layers 126 may be guided by the first roller strip 716a and the second roller strip 716b to pass through a small gap created between the pivoted lower ends of the respective first roller strip 716a and the second roller strip 716b.
[00117] In an embodiment, the angular distance between the first roller strip 716a and the second roller strip 716b may be varied according to the external diameter of the laminated tubular layers 126 and the internal diameter of the hollow chamber 704.
[00118] The angular distance between the first roller strip 716a and the second roller strip 716b may be adjusted by adjustment grooves (718a and 718b), hereinafter simply referred to as adjustment grooves 718, unless described otherwise. In an embodiment, the adjustment grooves 718 may be curved grooves to adjust the respective first roller strip 716a and the second roller strip 716b angularly with respect to their respective pivot points. In an alternative embodiment, a single adjustment groove 718 may be provided to adjust the angular distance between the first roller strip 716a and the second roller strip 716b, instead of separate adjustment grooves (718a and 718b).
[00119] The first roller strip 716a and the second roller strip 716b may be fastened at a required angle with the respective adjustment grooves 718a and 718b. According to an aspect of the present disclosure, the first roller strip 716a may be fixed by fastening it to the required angular position on the first adjustment groove 718a at a required angle. Similarly, the second roller strip 716b may be fixed by fastening it to the required angular position on the second adjustment groove 718b at a required angle.
[00120] Further, one or more supporting rollers 720 may be configured between the first roller strip 716a and the second roller strip 716b, and the winder 128.
[00121] In an embodiment, the one or more supporting rollers 720 may be further configured to pass the laminated tubular layers 126 in a serpentine manner to enable a natural convection cooling of the laminated tubular layers 126 before the unwinding. In an embodiment, the one or more supporting rollers 720 may range from one roller to twenty rollers. Similarly, the rollers may be configured at any suitable position to guide the laminated tubular layers 126 to the winder 128.
[00122] Further, a base 722 may be configured to support the lamination chamber, first roller strip 716a and the second roller strip 716b, and one or more supporting rollers 720. The base 722 may not be limited to any specific size and shape and may be any of the square, triangle, rectangle, semicircle, or any other shape. In a preferred embodiment, the base may be of a triangular shape formed by a plurality of supporting angles or supporting rods.
[00123] FIG. 8 is an electronic block diagram of the circular weaving loom machine, according to an aspect of the present disclosure.
[00124] Referring to FIG. 8, the control unit 802 is disclosed. The control unit 802 is configured to receive input values and signals from the temperature sensor 710 and the proximity sensor 712.
[00125] According to an aspect of the present disclosure, the temperature sensor 710 may be configured to continuously monitor the temperature within the hollow chamber 704 of the laminating chamber 124. The continuous temperature data measured by the temperature sensor 710 may be transmitted to the control unit 802. Further, the control unit 802 may control the operations of heaters 706 based on the data received from the temperature sensor 710. According to an embodiment of the present disclosure, the temperature within the laminating chamber 124 may be set to a predetermined temperature. The predetermined temperature may be selected based on the melting temperature of the inner layer 114 and the outer layer 112. The predetermined temperature may be set such that it does not reach near the melting temperature of the inner layer 114, but heats the inner layer 114 just enough that the inner layer 114 may stick to the outer layer 112.
[00126] Henceforth, to maintain a constant temperature, the control unit 802 may control the heaters 706 to heat them up to the predetermined temperature and shut off the heaters 706 when the temperature within the laminating chamber 124 reaches an upper threshold. Similarly, the control unit 802 may turn on the heaters 706 when the temperature within the laminating chamber 124 reaches a lower threshold.
[00127] In an embodiment, the value of the upper threshold and the lower threshold may be fed into the control unit 802 as per the requirement. Further, the value of the upper threshold and the lower threshold fed into the control unit 802 may be changed according to the type of material of the inner layer 114 and the outer layer 112.
[00128] Further, the temperature sensors 710 may be, but not limited to, J-type thermocouple, K-type thermocouple, other types of thermocouple, resistance temperature detectors, pyrometers, thermistors, or any other suitable type of temperature sensor.
[00129] The proximity sensor 712 may be configured to detect distance of the nested tubular layer 120, thereby determining the diameter or the width of the nested tubular layers 120, passing out from the hollow chamber 704. The width or the diameter of the nested tubular layers 120 is determined to monitor and control deflation of the nested tubular layers 120.
[00130] For example, the nested tubular layers 120, when passing through the laminating chamber 124 may get damaged or burned, and this may cause the air trapped between the first roller strip 620a and the second roller strip 620b, and the first roller strip 716a and the second roller strip 716b, to escape. The escaping of the air may not inflate the nested tubular layers 120 properly, and the nested tubular layers 120 may not touch the heaters. This may further hinder the lamination of the nested tubular layers 120 and result in improper lamination of the nested tubular layers 120. Further, this may also affect the alignment of the nested tubular layers 120 and cause damage to laminated tubular layers 126.
[00131] The proximity sensor 712 may be configured to detect the diameter or the width of the laminated tubular layers 126, passing out from the hollow chamber 704, and detect a reduction in the diameter or the width of the laminated tubular layers 126, which may indicate a leak of the air from the inflated nested tubular layers 120. The proximity sensor 712 may transmit the captured data to the control unit 802. The control unit 802 may, upon receiving the data corresponding to the reduced diameter or the width of the laminated tubular layers 126, control an actuator to allow a passage of the air from the bottom of the laminating chamber 124 towards the top of the laminating chamber 124, which may inflate the nested tubular layers 120 within the laminating chamber 124 to enable a contact between the nested tubular layers 120 and the heaters 704.
[00132] In an embodiment, another proximity sensor (not shown) may be configured near the first nip 116 or the second nip 118, or the expansion unit 122 to detect the diameter or the width of the nested tubular layers 120, passing through the expansion unit 122. The proximity sensor may detect the data corresponding to the diameter or the width of the nested tubular layers 120, and transmit the data to the control unit 802. Further, the control unit 802 may control the actuation of the actuation mechanism 504, that may further change the position of the second nip 118 from pinching position to released position, or from released position to pinching position.
[00133] The proximity sensor 712 may be, but may not be limited to, infrared (IR) proximity sensors, ultrasonic proximity sensors, capacitive proximity sensors, laser distance sensors, or any other suitable type of proximity sensor.
[00134] In an embodiment, the control unit 802 may be a processor. Further, the processor may be a microprocessor. In alternative embodiments, the control unit 802 may be a controller, a microcontroller, a state machine, or a combination of the same, or the like. The control unit 802 may include electrical circuitry configured to process computer-executable instructions. In another embodiment, the control unit 802 may include a device that performs logic operations without processing computer-executable instructions. Furthermore, the control unit 802 may also comprise a combination of computing devices, for example, a combination of a digital signal processor (DSP) and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Further, the control unit 802 may also include primarily analog components.
[00135] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.
[00136] The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure.
[00137] Throughout this specification, plural instances may implement components, operations, or structures described as a single instance. Although individual operations of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently, and nothing requires that the operations be performed in the order illustrated. Structures and functionality presented as separate components in example configurations may be implemented as a combined structure or component.
[00138] The embodiments, examples, and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible. The terms "an embodiment", "embodiment", "embodiments", "the embodiment", "the embodiments", "one or more embodiments", "some embodiments", and "one embodiment" mean "one or more (but not all) embodiments of the invention(s)" unless expressly specified otherwise.
[00139] Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the subject matter herein. In addition, the term “each” used in the specification does not imply that every or all element in a group need to fit the description associated with the term “each”. For example, “each member is associated with element A” does not imply that all members are associated with element A. Instead, the term “each” only implies that a member (of some of the members), in a singular form, is associated with an element A.
[00140] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the patent rights. It is therefore intended that the scope of the patent rights be limited not by this detailed description, but rather by any claims that are issued on an application based hereon. Accordingly, the disclosure of the embodiments is intended to be illustrative, but not limiting, of the scope of the patent rights.
LIST OF REFERENCE NUMERALS
102: a circular weaving loom machine
104: a plurality of bobbins
106: an unwinder unit
108: a circular weaving loom
110: an insertion unit
112: an outer layer
114: an inner layer
116: a first nip
118: a second nip
120: nested tubular layers
122: an expansion unit
124: a laminating chamber
126: laminated tubular layers
128: a winder
202: an unwinder shaft
204: one or more braking bearings
206: a brake lever
208: at least one guiding roller
210: base
302: at least one guiding roller
304: a bottom housing
306: a bottom housing support member
308: a bottom housing support member
310: a guiding pipe
402: spreader unit
404: a top housing
406: an outer layer guiding link
408: a supporting link
410: at least one guiding roller
412: connecting links
414: horns
502: laminating device
504: actuation mechanism
602: a first roller
604: a second roller
606a: one or more rollers
606b: one or more rollers
608a: a first roller strip
608b: a second roller strip
610a: an adjustment groove
610b: an adjustment groove
612: housing
614: a first roller
616: a second roller
618a: one or more rollers
618b: one or more rollers
620a: a first roller strip
620b: a second roller strip
702: a wall
704: a hollow chamber
706: one or more heaters
708: a clamp
710: a temperature sensor
712: a proximity sensor
714a: one or more rollers
714b: one or more rollers
716a a first roller strip
716b a second roller strip
718a a roller adjuster
718b a roller adjuster
720: one or more supporting rollers
722: a base
802: control unit

, Claims:We Claim,
1. A laminating device (502), comprising:
an expansion unit (122) configured to:
receive nested tubular layers (120) comprising an inner layer (114) and an outer layer (112), wherein
the inner layer (114) is loosely nested within the outer layer (112); and
inflate the nested tubular layers (120) to radially expand and align the inner layer (114) and the outer layer (112); and
a laminating chamber (124) comprising:
a wall (702) defining a hollow chamber (704); and
one or more heaters (706) mounted on an inner surface of the wall (702), wherein the laminating chamber (124) is configured to:
receive the aligned nested tubular layers (120) fed from the expansion unit (122) into the hollow chamber (702); and
heat the aligned nested tubular layers (120) to laminate the inner layer (114) to the outer layer (112).

2. The laminating device (502) as claimed in claim 1, wherein the outer layer (112) is a layer of a tubular woven fabric.

3. The laminating device (502) as claimed in claim 1, wherein the inner layer (114) is a layer of a tubular liner.

4. The laminating device (502) as claimed in claim 3, wherein the tubular liner is a tubular plastic film.

5. The laminating device (502) as claimed in claim 1, wherein the expansion unit (122) comprises a first nip (116), and a second nip (118) distantly configured to the first nip (116).

6. The laminating device (502) as claimed in claim 5, wherein the second nip (118) is adjustable to transition between a released position and a pinching position.

7. The laminating device (502) as claimed in claim 5, wherein the expansion unit (122) is configured to
pinch the nested tubular layers (120) between the first nip (116) and the distant second nip (118) to trap air within the pinched nested tubular layers (120) and inflate the nested tubular layers (120).

8. The laminating device (502) as claimed in claim 6, wherein
in a released position, the second nip (118) is configured to permit air to enter within the nested tubular layers (120) between the first nip (116) and the second nip (118), from the nested tubular layers (120) across the second nip (118), and
in a pinching position, the second nip (118) is configured to pinch the nested tubular layers (120) to trap the entered air to inflate the nested tubular layers (120).

9. The laminating device (502) as claimed in claim 1, wherein the expansion unit (122) further comprises an actuation mechanism (504) configured to adjust the second nip (118).

10. The laminating device (502) as claimed in claim 9, wherein the actuation mechanism (504) is at least a mechanical actuator, a hydraulic actuator, a pneumatic actuator, or an electronic actuator.

11. The laminating device (502) as claimed in claim 5, further comprises one or more rollers (716a & 716b) configured at a side of the laminating chamber (124) opposite to a side of the second nip (118), wherein
the one or more rollers (716a & 716b) are configured to receive the aligned nested tubular layers (120) from the second nip (118) through the laminating chamber (124) to laminate the inner layer (114) and the outer layer (112).

12. The laminating device (102) as claimed in claim 11, wherein the aligned nested tubular layers (120) are inflated between the second nip (118) and the one or more rollers (716a & 716b) to touch the one or more heaters (706) for lamination.

13. The laminating device (502) as claimed in claim 1, wherein the one or more heaters (706) are at least one of ceramic heaters, mica heaters, ceramic mica heaters, or any other type of heaters.

14. The laminating device (502) as claimed in claim 1, comprises a temperature sensor (712) configured within the hollow chamber (704) to monitor the temperature within the hollow chamber (704).

15. The laminating device (502) as claimed in claim 1, comprises a proximity sensor (714) configured at a lower end of the hollow chamber (704) to detect a diameter or a width of the nested tubular layers (120).

16. The laminating device (502) as claimed in claim 1, comprises a control unit (802) which is configured to:
receive data from the temperature sensor (710);
control operations of the one or more heaters (706) based on the data received from the temperature sensor (710), wherein
the operations of the one or more heaters (706) are controlled to maintain a preset level of temperature within the laminating chamber (124).

17. A circular weaving loom machine (102) comprising:
a circular weaving unit (108) configured to form an outer layer (112);
an insertion unit (110) configured under the circular weaving unit (108) to insert an inner layer (114) into the formed outer layer (112) to form nested tubular layers (120);
a laminating device (102) comprising:
an expansion unit (122) configured to
receive the nested tubular layers (120) comprising the inner layer (114) and the outer layer (112), wherein
the inner layer (114) is loosely nested within the outer layer (112); and
inflate the nested tubular layers (120) to radially expand and align the inner layer (114) and the outer layer (112); and
a laminating chamber (124) comprising:
a wall (702) defining a hollow chamber (704); and
one or more heaters (706) mounted on an inner surface of the wall (702), wherein the laminating chamber (124) is configured to:
receive the aligned nested tubular layers (120) fed from the expansion unit (122) into the hollow chamber (704); and
heat the aligned nested tubular layers (120) to laminate the inner layer (114) to the outer layer (112).

18. The circular weaving loom machine (102) as claimed in claim 17, wherein the outer layer (112) is a layer of a tubular woven fabric.

19. The circular weaving loom machine (102) as claimed in claim 17, wherein the inner layer (114) is a layer of a tubular liner.

20. The circular weaving loom machine (102) as claimed in claim 19, wherein the tubular liner is a tubular plastic film.

21. The circular weaving loom machine (102) as claimed in claim 17, wherein the expansion unit (122) comprises a first nip (116), and a second nip (118) distantly configured to the first nip (116).

22. The circular weaving loom machine (102) as claimed in claim 21, wherein the second nip (118) is adjustable to transition between a released position and a pinching position.

23. The circular weaving loom machine (102) as claimed in claim 21, wherein the expansion unit (122) is configured to
pinch the nested tubular layers (120) between the first nip (116) and the distant second nip (118) to trap air within the pinched nested tubular layers (120) and inflate the nested tubular layers (120).

24. The circular weaving loom machine (102) as claimed in claim 22, wherein
in a released position, the second nip (118) is configured to permit air to enter within the nested tubular layers (120) between the first nip (116) and the second nip (118), from the nested tubular layers (120) across the second nip (118), and
in a pinching position, the second nip (118) is configured to pinch the nested tubular layers (120) to trap the entered air to inflate the nested tubular layers (120).

25. The circular weaving loom machine (102) as claimed in claim 17, wherein the expansion unit (122) further comprises an actuation mechanism (504) configured to adjust the second nip (118).

26. The circular weaving loom machine (102) as claimed in claim 25, wherein the actuation mechanism (504) is at least a mechanical actuator, a hydraulic actuator, a pneumatic actuator, or an electronic actuator.

27. The circular weaving loom machine (102) as claimed in claim 21, further comprises one or more rollers (716a & 716b) configured at a side of the laminating chamber (124) opposite to a side of the second nip (118), wherein
the one or more rollers (716a & 716b) are configured to receive the aligned nested tubular layers (120) from the second nip (118) through the laminating chamber (124) to laminate the inner layer (114) and the outer layer (112).

28. The circular weaving loom machine (102) as claimed in claim 27, wherein the aligned nested tubular layers (120) are inflated between the second nip (118) and the one or more rollers (716a & 716b) to touch the one or more heaters (706) for lamination.

29. The circular weaving loom machine (102) as claimed in claim 17, wherein the one or more heaters (706) are at least one of ceramic heaters, mica heaters, ceramic mica heaters, or any other type of heaters.

30. The circular weaving loom machine (102) as claimed in claim 17, comprises a temperature sensor (710) configured within the hollow chamber (704) to monitor the temperature within the hollow chamber (704).

31. The circular weaving loom machine (102) as claimed in claim 17, comprises a proximity sensor (712) configured at a lower end of the hollow chamber (704) to detect a diameter or a width of the nested tubular layers (120).

32. The circular weaving loom machine (102) as claimed in claim 17, comprises a control unit which is configured to:
receive data from the temperature sensor (710);
control operations of the one or more heaters (706) based on the data received from the temperature sensor (710), wherein
the operations of the one or more heaters (706) are controlled to maintain a preset level of temperature within the laminating chamber (124).