A four-ply network process for carpet nylon network yarn

Abstract

This invention discloses a four-strand web spinning process for carpet nylon web yarns on a spinning machine. This process provides carpet manufacturers with a solution where, when producing samples or developing new patterns, if the four-strand nylon web yarns have three or two colors, the original two- or three-step web spinning process can be replaced by a one-step web spinning process when reordering, by spinning the same fineness and color. This process considers both the rapid preparation of yarn during the initial sample production stage to ensure quick delivery of large-scale samples and gain a competitive edge in the market, and the increased production efficiency of enterprises for large-volume orders in the later stages, significantly improving spinning efficiency, shortening yarn preparation time, and providing technical support for order delivery. The entire process greatly saves production costs for enterprises and improves their survival capabilities.

Description

Technical Field

[0001] This invention relates to the field of textile technology, and in particular to a four-strand web process for nylon web yarn machines used in carpets. Background Technology

[0002] Currently, carpet manufacturers produce most carpets based on customer samples, with the exception of a portion kept in stock. The process from order acceptance to final production is as follows: carpet factory receives customer samples—sample parameter design—mass sample yarn preparation—mass sample production—customer confirmation of mass sample—customer places order—order process parameter design—order yarn preparation—order production. The most challenging aspect of this process is yarn design and preparation. To save costs and shorten production time, some carpet manufacturers select different colors and finenesses of multi-strand nylon filament yarn from their existing inventory and use a web-forming machine to web the yarn based on the customer's sample. Due to the limited number of spindles on the web-forming machine, this typically requires two or three web-forming steps to produce yarn that matches the customer's sample. If, after the customer confirms the sample's effect and places a formal order, the carpet manufacturer still uses the same production process for the sample nylon filament yarn to mass-produce the ordered yarn, it will result in low spinning machine efficiency, cumbersome web-forming steps after spinning, and an excessively long yarn preparation cycle, affecting customer delivery times and causing a series of problems. Summary of the Invention

[0003] The purpose of this invention is to provide a four-strand network process for nylon network yarns used in carpets, in order to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A four-strand web-forming process for nylon web-forming yarns used in carpets involves using a three-spindle web-forming machine to web four strands of nylon web-forming yarns. The specific steps are as follows:

[0006] When producing samples or developing new patterns, if the colors of the four nylon network yarns are A, B, C, and D respectively, then the first step is to create a three-strand network of A, B, and C, and the second step is to create a two-strand network of ABC and D. This process is repeated when placing a new order.

[0007] When producing samples or developing new patterns, if the colors of the four nylon network yarns are A, A, B, and C, then the first step is to use two-strand A+A network, and the second step is to use three-strand 2A+B+C network. When placing an order again, this process can be used flexibly according to the order quantity. If the amount of yarn used for color A is large or there is no stock, and it is necessary to re-spin yarn, then directly spin 2A. 2A is color A with twice the fineness. The 2A+B+C network can be completed in one step.

[0008] When producing samples or developing new patterns, if the colors of the four nylon network yarns are A, A, A, and B, then the first step is to use a three-strand network of A+A+A, and the second step is to use a two-strand network of 3A+B. When placing an order again, this process can be used flexibly according to the order quantity. If the amount of yarn used for color A is large or there is no stock, and it is necessary to respin yarn, 3A can be spun directly. 3A is color A with three times the fineness. The 3A+B network can be completed in one step.

[0009] When producing samples or developing new patterns, if the colors of the four nylon network yarns are A, A, B, and B respectively, the first step is to use two-strand A+A network yarn, the second step is to use two-strand B+B network yarn, and the third step is to use two-strand 2A+2B network yarn. 2B is the B color with twice the fineness. When placing a new order, this process can be used flexibly according to the order quantity. If the amount of yarn used for A and B colors is large or there is no stock, and it is necessary to re-spin yarn, 2A and 2B can be spun directly. The 2A+2B network can be completed in one step.

[0010] When producing samples or developing new patterns, the four methods mentioned above are used to perform off-machine networking based on the color of the four strands of nylon network yarn to obtain the final finished yarn. When placing a new order, the four off-machine networking processes mentioned above are flexibly applied according to the order quantity.

[0011] As a further technical solution of the present invention: a three-spindle networking machine is used to network four strands of nylon network yarn off-machine.

[0012] As a further technical solution of the present invention: the final finished yarn is obtained by performing offline networking in two or three steps based on the color difference of the four strands of nylon network yarn.

[0013] As a further technical solution of the present invention: the two-step or three-step process of obtaining the finished yarn from the machine network follows the principle that "if the four strands of nylon network yarn have the same color, the network yarn of the same color must first network itself, and then network with other different colors".

[0014] As a further technical solution of the present invention: the two or three self-networked yarns of the same color network yarns can be replaced by single network yarns of the same color and of the same fineness.

[0015] As a further technical solution of the present invention: when producing samples or developing new patterns, four strands of nylon network yarn, two or three strands of network yarn of the same color that are self-networked can be replaced by a single network yarn of the same color and of the same fineness. Correspondingly, the original two-step or three-step networking process can be replaced by a one-step networking process.

[0016] As a further technical solution of the present invention: network air pressure 2-6 bar, machine speed 400-800 m / min.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] This invention provides a four-strand web spinning process for carpet nylon web yarns on a spinning machine. For carpet manufacturers, this process allows for the production of samples or the development of new patterns. If the four-strand nylon web yarns have three or two colors, the original two- or three-step web spinning process can be replaced by a one-step web spinning process when reordering, using yarns of the same fineness and color. This process considers both the rapid preparation of yarn during the initial sample production stage to ensure quick delivery of large-scale samples and gain a competitive edge in the market, and the increased production efficiency of companies ordering large quantities later. It significantly improves the spinning efficiency of the spinning process, shortens yarn preparation time, and provides technical support for order delivery. The entire process greatly saves production costs and enhances the company's survival capabilities. Detailed Implementation

[0019] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] A four-strand web forming process for nylon web yarns used in carpets involves using a three-spindle web forming machine to form four strands of nylon web yarns. The web forming air pressure is 2-6 bar, and the machine speed is 400-800 m / min. The process requires two or three steps to complete.

[0021] ① When producing samples or developing new patterns, if the four nylon mesh yarns are A, B, C, and D respectively, the first step is to mesh the three yarns A, B, and C, selecting appropriate meshing air pressure and meshing machine speed according to the yarn fineness to obtain semi-finished product ABC; the second step is to mesh the two yarns ABC+D, selecting appropriate meshing air pressure and meshing machine speed according to the finished yarn fineness to obtain finished product ABCD. This process is repeated when placing reorders.

[0022] ② When producing samples or developing new patterns, if the four nylon network yarns are A, A, B, and C respectively, the first step is to network two strands (A+A). Based on the yarn fineness, select appropriate network air pressure and network machine speed to obtain semi-finished product 2A. The second step is to network three strands (2A+B+C). Based on the finished yarn fineness, select appropriate network air pressure and network machine speed to obtain finished product 2ABC. When placing a reorder, this process can be flexibly applied according to the order quantity. If the amount of yarn used for color A is large or there is no stock, and respinning is required, 2A (i.e., color A with twice the fineness) can be spun directly, and the network process 2A+B+C can be completed in one step.

[0023] ③ When producing samples or developing new patterns, if the four nylon mesh yarns are A, A, A, and B respectively, the first step is to use a three-strand mesh (A+A+A). Based on the yarn fineness, select appropriate mesh air pressure and mesh machine speed to obtain semi-finished product 3A. The second step is to use a two-strand mesh (3A+B). Based on the finished yarn fineness, select appropriate mesh air pressure and mesh machine speed to obtain finished product 3AB. When placing a reorder, this process can be flexibly applied according to the order quantity. If the amount of yarn used for color A is large or there is no stock, and respinning is required, 3A (i.e., color A with three times the fineness) can be spun directly, and the 3A+B mesh can be completed in one step off the machine.

[0024] ④ When producing samples or developing new patterns, if the four nylon mesh yarns are A, A, B, and B respectively, the first step is to mesh two strands of A+A, and the second step is to mesh two strands of B+B. For these two steps, select appropriate meshing air pressure and meshing machine speed according to the yarn fineness to obtain semi-finished products 2A and 2B. The third step is to mesh two strands of 2A+2B. When placing a reorder, this process can be flexibly applied according to the order quantity. If the amount of yarn used for colors A and B is large or there is no stock, and respinning is required, 2A (i.e., color A with twice the fineness) and 2B (i.e., color B with twice the fineness) can be spun directly, and the meshing of 2A+2B can be completed in one step.

[0025] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0026] The working principle is as follows:

[0027] I. Customer Sample Yarn Design and Preparation:

[0028] The product design department received a sample from a customer. The sample yarn was nylon mesh yarn with a fineness of 4600 dtex. They searched their inventory and found that combinations of colors A, B, and C in stock closely resembled the sample yarn. The process engineer designed the mesh fabrication process.

[0029]

[0030]

[0031] The process engineer calculated that the yarn consumption for the large-scale sample was 50 kg.

[0032] The yarn preparation workshop produces 50 kg of finished yarn according to the process requirements.

[0033] II. Production of Large-Scale Samples:

[0034] The carpet weaving workshop hangs the yarn according to the weaving process requirements, sets reasonable machine adjustment parameters according to customer samples, and weaves the raw carpet after the machine adjustment effect meets the standards. The raw carpet is then finished.

[0035] III. Customer Confirmation of Large-Scale Samples:

[0036] After receiving the large-format sample, the customer confirmed the pattern effect and placed an order for 3,000 square meters.

[0037] IV. Ordering and production process notification;

[0038] The order is for 3000 square meters. The process engineer calculated that the yarn consumption is 18000KG, of which color A requires 3913KG, color B requires 10174KG, and color C requires 3913KG.

[0039] V. Preparation of yarn for ordering:

[0040] Due to the large amount of yarn used for colors A, B, and C, the spinning workshop re-spun the yarn. The yarn fineness of colors A and C remained unchanged at 1000 dtex, while the yarn fineness of color B was adjusted from 1300 dtex to 2600 dtex, doubling the spinning efficiency of color B.

[0041]

[0042]

[0043] By adjusting the fineness of the B-color spinning process, the web-making process is reduced from two steps to one, thus obtaining the finished yarn. After subsequent raw felt weaving and finishing processes, the ordered production is completed on schedule.

[0044] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment have been appropriately combined to form other embodiments that are easy for those skilled in the art to understand.

Claims

1. A carpet nylon net yarn machine down four ply net process characterized by, The four strands of nylon web are webbed off-machine using a three-spindle webping machine. The specific steps are as follows: When producing samples or developing new patterns, if the colors of the four nylon network yarns are A, B, C, and D respectively, then the first step is to create a three-strand network of A, B, and C, and the second step is to create a two-strand network of ABC and D. This process is repeated when placing a new order. When producing samples or developing new patterns, if the four nylon network yarns are A, A, B, and C respectively, the first step is to use two-strand A+A network, and the second step is to use three-strand 2A+B+C network. When placing an order again, this process is used according to the order quantity. If the amount of yarn used for color A is large or there is no stock, and it is necessary to respin yarn, directly spin 2A. 2A is color A with twice the fineness. The 2A+B+C network can be completed in one step. When producing samples or developing new patterns, if the colors of the four nylon network yarns are A, A, A, and B, then the first step is to use a three-strand network of A+A+A, and the second step is to use a two-strand network of 3A+B. When placing an order again, this process is used according to the order quantity. If the amount of yarn used for color A is large or there is no stock, and it is necessary to respin yarn, 3A can be spun directly. 3A is three times the fineness of color A. The 3A+B network can be completed in one step. When producing samples or developing new patterns, if the four nylon network yarns are A, A, B, and B respectively, the first step is to create an A+A two-strand network, the second step is to create a B+B two-strand network, and the third step is to create a 2A+2B two-strand network. 2B refers to a B color with twice the fineness. When placing a reorder, this process can be used according to the order quantity. If the amount of yarn used for A and B colors is large or there is no stock, and respinning is required, 2A and 2B can be spun directly, and the 2A+2B network can be completed in one step. When producing samples or developing new patterns, the four methods mentioned above are used to perform the offline networking process according to the color of the four nylon network yarns to obtain the final finished yarn. When placing a new order, the four methods mentioned above are used to perform the offline networking process according to the order quantity.

2. The four-strand web fabrication process for nylon web yarn in carpets according to claim 1, characterized in that, Based on the color difference of the four nylon network filaments, the final finished yarn is obtained by two or three steps of off-machine networking.

3. The four-strand web forming process for nylon web yarn in carpets according to claim 1, characterized in that, Both two-step and three-step methods for obtaining finished yarn from the machine network follow the principle that "if four strands of nylon network yarn have the same color, the network yarn of the same color must be networked by itself first, and then networked with other yarns of different colors." 4. The four-strand web forming process for nylon web yarn in carpets according to claim 1, characterized in that, Two or three self-networked yarns of the same color can be replaced by a single network yarn of the same color and of the same fineness.

5. The four-strand web forming process for nylon web yarn in carpets according to claim 1, characterized in that, When producing samples or developing new patterns, four strands of nylon network yarn, two or three strands of network yarn of the same color that form a self-network are replaced by a single network yarn of the same color and of the same fineness. Correspondingly, the original two-step or three-step network process is replaced by a one-step network process.

6. The four-strand web forming process for nylon web yarns used in carpets according to any one of claims 1-5, characterized in that, Network air pressure 2-6 bar, machine speed 400-800 m / min.

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