A method for the efficient production of industrial filter fabrics
By adopting continuous feeding and carding technology using silk fibers and a high-efficiency carding machine, the problem of low production efficiency in the silk spinning industry has been solved, enabling the production of industrial filter fabrics with high strength, abrasion resistance, and dimensional stability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- JIANGNAN UNIV
- Filing Date
- 2026-02-11
- Publication Date
- 2026-05-29
Smart Images
Figure CN122105697A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of spinning technology, and in particular to a highly efficient production method for industrial filter fabrics. Background Technology
[0002] As a crucial component of the textile industry, silk spinning is a major industry in my country. However, due to outdated technology and slow equipment upgrades, production techniques are generally low, resulting in high energy and raw material consumption, labor intensity, and low productivity. Currently, most silk spinning enterprises still employ traditional processes and equipment, especially in the cotton processing section, where manual and semi-mechanized operations remain prevalent.
[0003] High-density silk fabrics are suitable for use in precision instrument filtration. Industrial filtration silk fabrics are high-performance filter media made through special processing, utilizing the excellent natural properties of silk. They aim to stably intercept particles in harsh environments, including high temperatures, acids, alkalis, and abrasion. The processing emphasizes how to transform the natural advantages of silk, such as fiber surface properties, heat resistance, and mechanical strength, into filtration advantages.
[0004] When silk fabrics are used in industrial filtration, certain requirements are placed on the physical and mechanical properties of the fabric, including high strength and abrasion resistance. The warp and weft breaking strength and tear strength must be very high to withstand repeated stretching, bending and friction during filtration and cleaning, thus extending the service life of the fabric. Excellent dimensional stability is required, which means that the fabric's thermal shrinkage and creep must be extremely low to ensure dimensional and shape stability under operating temperature and humidity conditions, preventing it from becoming loose or too tight on the filter bed. Suitable surface characteristics for filtration are also required, such as a smooth surface, good peelability, easy filter cake removal, and convenient cleaning and regeneration.
[0005] There are two types of carding in silk spinning: combed and circular carding. Combed carding has a higher degree of mechanization, higher efficiency, and a shorter process flow. However, because it uses a roller carding machine to coarsely comb long fibers, it produces a large number of knots. In addition, due to the high fiber strength, the fibers are prone to tangling during carding. Therefore, combed carding is generally used for processing medium and low-grade raw materials. Circular carding, on the other hand, requires manual operation, is more labor-intensive, and has a more complex process than combed carding. However, it is better suited to the characteristics of long, easily tangled fibers in fine silk. During processing, all parts of the silk are finely combed, effectively removing cotton particles and impurities, improving fiber straightness and parallelism, making it suitable for processing medium and high-grade raw materials.
[0006] Carding is a crucial step in cotton manufacturing, directly affecting the quality of the finished cotton and determining the level of carding, which in turn determines the quality of the yarn, especially its strength and elongation characteristics. During circular carding, cotton fibers are manually placed into a carding plate and then carded by the carding cylinder and front and rear carding rollers, thereby improving the straightness, parallelism, and separation of the fibers to produce finished cotton. The finished cotton is then manually removed and sent to the next process. Therefore, the circular carding process requires a large amount of manual labor, resulting in low production efficiency. Summary of the Invention
[0007] The purpose of this invention is to provide an efficient production method for industrial filter fabrics. Using silk fibers as raw materials, a high-efficiency carding machine for silk spinning is employed to separately hold and card the two ends of the continuously fed, cut silk fibers, thereby improving the carding effect and enhancing the overall quality of the yarn, especially the strength and elongation of the yarn. This results in the efficient production of industrial filter fabrics that combine high strength and abrasion resistance, excellent dimensional stability, and smooth surface properties.
[0008] This invention provides a highly efficient production method for industrial filter fabrics, comprising the following steps: Step 1: Fiber sheet formation: Silk fibers are refined into clean, dry cotton through processes including degumming, bleaching and reduction, and humidification; then, through blending, opening, and cutting, they are made into bar cotton suitable for carding; finally, cotton sheets are obtained through a high-efficiency carding machine including a continuous feeding device and a continuous carding device. The continuous feeding device includes a rear passive feeding roller and a front active feeding roller, which are rotatably supported by rear and front support frames, and a conveyor belt is wrapped around the two. The continuous carding device includes a drive roller, with a gripping carding device located below its side and a free carding device located above it, both of which fully cover the circumference of the side of the drive roller. The holding and combing device includes a pressing device that fully covers the lower circumference of the side of the driving roller. The pressing device includes identical inner and outer pressing arc supports. Between the two is an extraction roller that slides along the inner and outer pressing arc supports and rotates along its own axis. A combing roller is set directly below each mounting device, and a holding and combing needle cloth is set on it. The free carding device includes a carding plate that completely covers the upper circumference of the side of the drive roller without any gaps, and a free carding needle cloth is arranged on the side facing the drive roller; The fiber is continuously fed into the conveyor belt, and the roller rotates counterclockwise during the feeding process. The fiber enters between the roller and the pressing device. Under the pressing and pulling of the roller and the extraction roller, the fiber is straightened and combed at the front end in the pressing device. Then the feeding stops and the roller rotates clockwise. Under the pressure of the roller and the extraction roller, the rear end straightens and combs within the pressing device. During the straightening and combing process at both the front and rear ends, the fiber is transferred between various installation devices under the drive of the drive roller; During the straightening and carding process, the fibers that are driven to the top of the drive roller enter between the drive roller and the carding plate. The fibers are driven by the drive roller, causing the free carding needle cloth to be randomly inserted between the fibers, improving the separation between the fibers. When the fibers are removed from the free carding needle cloth, the fibers that are not fully straightened are further straightened. Keep the fiber feeding stopped and straighten and comb the front and back ends for a certain period of time, then remove the combed silk fibers by the extraction rod; Step 2: Fiber spinning: The cotton sheet is stretched into a certain length of cotton strip in one pass, and then further connected and stretched into a continuous cotton sliver through sliver making; it is then finished by four passes of drawing to obtain a fine cotton sliver; it is then processed by a roving machine of cotton spinning to obtain silk roving; and it is then processed by a ring spinning machine of cotton spinning with added mesh rings to obtain silk yarn. Step 3: Plying the single yarn: Two or more silk yarns are combined and twisted to make silk ply yarn, which is then singed twice to make silk ply yarn ready to be woven. Step 4: Fabric processing: A portion of the silk filaments to be woven are warped to form a warp beam, and the warp beam and the silk filaments to be woven are then woven to produce a high-density industrial filter fabric. Step 5: Post-processing: After refining and heat setting to obtain a stable pore structure, the pores are further precisely controlled by embossing, and then the industrial filter fabric is produced by cutting and sewing.
[0009] In the efficient production method of industrial filter fabric described above, preferably, a rapier loom is used in the weaving process, and a plain weave structure is adopted.
[0010] In the above-described efficient production method of industrial filter fabric, preferably, the rear passive feed roller and the front active feed roller include an intermediate roller shaft and an outer roller sleeve. The intermediate roller shaft is a solid cylindrical structure made of steel, and the outer roller sleeve is an annular structure made of hard rubber. The inner diameter of the outer roller sleeve is the same as the outer diameter of the intermediate roller shaft, and the length of the outer roller sleeve is less than the length of the intermediate roller shaft. The outer roller sleeve is fixedly fitted onto the intermediate roller shaft, and the two ends of the outer roller sleeve after being fitted maintain a certain and equal distance from the two ends of the corresponding intermediate roller shaft. The rear passive feed roller is supported by a rear support frame, which is a cuboid structure and is set vertically on the ground. An inner rear connecting rod is fixedly connected to the inward side of the upper side of the rear support frame, and an outer rear connecting rod is fixedly connected to the outward side of the upper side of the rear support frame. The inner end of the intermediate roller shaft of the rear passive feed roller extending out of the outer roller sleeve is connected to the inner rear connecting rod by a bearing, and the outer end of the intermediate roller shaft of the rear passive feed roller extending out of the outer roller sleeve is connected to the outer rear connecting rod by a bearing. A certain distance is maintained between the outer roller sleeve of the rear passive feed roller and the upper side of the rear support frame after the connection. The front active feed roller is supported by a front support frame, which is a cuboid structure and is set in a downward inclined state. The front support frame and the rear support frame are connected to each other by a middle connecting plate, which is also a cuboid structure. One side of the middle connecting plate is fixedly connected to the rear support frame, and the other side is fixedly connected to the front support frame. The lower side of the front support frame maintains a certain distance from the ground. The front side of the front support frame is smooth. A front inner connecting rod is fixedly connected to the inward side of the upper side of the front support frame, and a front outer connecting rod is fixedly connected to the outward side of the upper side of the front support frame. The inner end of the intermediate roller shaft of the front active feed roller extending out of the outer roller sleeve is connected to the front inner connecting rod by a bearing, and the outer end of the intermediate roller shaft of the front active feed roller extending out of the outer roller sleeve is connected to the front outer connecting rod by a bearing. After connection, the outer roller sleeve of the front active feed roller maintains a certain distance from the upper side of the front support frame. A conveyor belt is threaded between the rear passive feed roller and the front active feed roller. The conveyor belt is a flexible ring. The conveyor belt passes through the rear passive feed roller and the front active feed roller respectively, and the conveyor belt is in a taut state after being threaded. The front active feed roller is driven to rotate by a conveyor motor.
[0011] The efficient production method of industrial filter fabric as described above, wherein preferably, the pressing device includes an inner pressing arc support and an outer pressing arc support with identical structures; The inner pressing arc support is located on the inward side of the side circumference of the driving roller, and the outer pressing arc support is located on the outward side of the side circumference of the driving roller. The inner pressing arc support and the outer pressing arc support include an upper pressing arc and a lower pressing arc with the same structure. Both the upper pressing arc and the lower pressing arc are arc-shaped structures. The upper pressing arc and the lower pressing arc are parallel and parallel to the side arc of the driving roller directly opposite to them. The arc length of the side arc of the driving roller directly opposite to the upper pressing arc and the lower pressing arc is less than the main body length of the silk fiber being processed. The two ends of the upper pressing arc and the lower pressing arc are fixedly connected by the first pressing arc connecting rod and the second pressing arc connecting rod, respectively. An upper connecting groove is opened on the downward side of the upper pressing arc. The upper connecting groove does not penetrate the thickness of the upper pressing arc. A lower connecting groove is opened on the upward side of the lower pressing arc. The lower connecting groove does not penetrate the thickness of the lower pressing arc. The lower side of the lower pressing arc is fixedly connected to the pressing arc fixing ring through the pressing arc connecting rod. The pressing arc fixing ring is a circular ring. The pressing arc fixing ring of the inner pressing arc bracket is sleeved on the inner connecting shaft, and a certain gap is maintained between the inner connecting shaft and the inner connecting shaft. The inner connecting shaft is fixedly connected to the inner connecting shaft bracket through the inner connecting cylinder. The pressing arc fixing ring of the outer pressing arc bracket is sleeved on the outer connecting shaft, and a certain gap is maintained between the outer connecting shaft and the outer connecting shaft. The outer connecting shaft is fixedly connected to the outer connecting shaft bracket through the outer connecting cylinder.
[0012] In the efficient production method of the industrial filter fabric described above, preferably, an extraction roller is arranged between the inner pressing arc support and the outer pressing arc support. The extraction roller includes an extraction roller shaft and an extraction roller sleeve. The extraction roller shaft is a solid cylinder made of iron. The extraction roller sleeve is an annular structure made of rubber with a certain degree of soft elasticity. The length of the extraction roller sleeve is less than the length of the extraction roller shaft. The extraction roller sleeve is fixedly fitted onto the extraction roller shaft, such that both ends of the extraction roller shaft extend beyond the corresponding ends of the extraction roller sleeve, and the lengths of the extensions are the same. An inwardly embedded part is formed on the inward-facing end of the extraction roller shaft that extends beyond the extraction roller sleeve. The inner embedded groove surrounds a circumference of the side of the extraction roller shaft. The inner embedded end of the extraction roller shaft extending out of the extraction roller sleeve forms an inner embedded end with the inner embedded groove. An outer embedded groove is opened on the outer embedded end of the extraction roller shaft extending out of the extraction roller sleeve. The outer embedded groove surrounds a circumference of the side of the extraction roller shaft. The outer embedded end of the extraction roller shaft extending out of the extraction roller sleeve forms an outer embedded end with the outer embedded groove. The inner embedded end of the extraction roller is respectively embedded in the upper connecting groove of the upper pressing arc and the lower connecting groove of the lower pressing arc of the inner pressing arc bracket. The outer embedded end of the extraction roller is respectively embedded in the upper connecting groove of the upper pressing arc and the lower connecting groove of the lower pressing arc of the outer pressing arc bracket.
[0013] In the efficient production method of industrial filter fabric described above, preferably, the extraction roller sleeve of the connected extraction roller and the drive roller maintain a tight pressing contact.
[0014] In the efficient production method of industrial filter fabric described above, preferably, a carding roller is provided at the lower part of each pressing device. Each carding roller is located directly below the corresponding mounting device and is arranged at equal arc intervals along the outer side of the driving roller. The distance between each carding roller and the outer side of the driving roller remains the same. Each carding roller is driven by a unified transmission mechanism to rotate synchronously counterclockwise or clockwise, and the direction of rotation of the carding roller is the same as that of the driving roller. A holding carding needle cloth is provided on the outer side of the carding roller. The holding carding needle cloth is composed of carding needles. The carding needles are arranged at equal intervals along the length direction of the outer side of the carding roller to form rows of holding carding needles. Each row of holding carding needles is arranged at equal arc intervals along the circumferential direction of the outer side of the carding roller to form a complete holding carding needle cloth.
[0015] In the above-described efficient production method of industrial filter fabric, preferably, the free carding device includes a certain number of carding plates. The carding plates have an arc-shaped structure, and the circumference of the arc-shaped carding plate is consistent with the diameter of the side circumference of the driving roller. The two ends of the carding plate are fixedly connected to the fixing rings, and the fixing rings are fixedly connected to the machine table surface. The carding plates are arranged along the side circumference of the driving roller and completely cover the side circumference of the driving roller without gaps. Free carding needle cloth is provided on the side of the carding plate facing the driving roller.
[0016] In the efficient production method of industrial filter fabric described above, it is preferable to use high-strength yarns such as aramid or PTFE yarns during sewing.
[0017] Compared with existing technologies, this invention uses silk fibers as raw materials and employs a high-efficiency carding machine for silk spinning, which includes a continuous feeding device, a holding and carding device, and a free carding device. This enables the separate holding and carding of both ends of the continuously fed, cut silk fibers, as well as free carding, thereby improving the carding effect and enhancing the overall quality of the yarn, especially the strength and elongation of the yarn. This achieves the efficient production of industrial filter fabrics that combine high strength and abrasion resistance, excellent dimensional stability, and smooth surface properties. Attached Figure Description
[0018] Figure 1 This is a schematic diagram of the overall structure of the high-efficiency carding machine provided in an embodiment of the present invention.
[0019] Explanation of reference numerals in the attached figures: 1-Rear support frame, 2-Rear inner connecting rod, 3-Rear outer connecting rod, 4-Front support frame, 5-Rear passive feed roller, 6-Front active feed roller, 7-Conveyor belt, 8-Drive roller, 9-Inner pressing arc bracket, 10-Outer pressing arc bracket, 11-Upper pressing arc, 12-Lower pressing arc, 13-First pressing arc connecting rod, 14-Second pressing arc connecting rod, 15-Upper connecting groove, 16-Lower connecting groove, 17-Extraction roller shaft, 18-Extraction roller sleeve, 19-Card roller, 20-Card plate, 21-Front inner connecting rod, 22-Front outer connecting rod, 23-Middle connecting plate. Detailed Implementation
[0020] The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.
[0021] This invention provides a highly efficient method for producing industrial filter fabrics, comprising the following steps: Step 1: Fiber sheet formation: The selected silk fibers are successively refined through processes including degumming, bleaching and reduction, and humidification to obtain clean and dry cotton; then, through blending, opening, and cutting, cotton is made into combed cotton suitable for carding; the combed cotton is then processed by a high-efficiency carding machine to obtain cotton sheets suitable for stretching.
[0022] Reference Figure 1 As shown, along the direction of fiber movement within the high-efficiency carding machine, from back to front, it includes a continuous feeding device and a continuous carding device.
[0023] The continuous feeding device includes a rear passive feeding roller 5 and a front active feeding roller 6.
[0024] The rear passive feed roller 5 and the front active feed roller 6 have the same structure. Both include an intermediate roller shaft and an outer roller sleeve. The intermediate roller shaft is a solid cylindrical structure made of steel. The outer roller sleeve is an annular structure made of hard rubber. The inner diameter of the outer roller sleeve is the same as the outer diameter of the intermediate roller shaft, and the length of the outer roller sleeve is less than the length of the intermediate roller shaft. The outer roller sleeve is fixedly fitted onto the intermediate roller shaft, and the two ends of the outer roller sleeve maintain a certain and equal distance from the two ends of the corresponding intermediate roller shaft. The rear passive feed roller 5 is supported by a rear support frame 1, which is a rectangular parallelepiped structure and is set vertically. On the ground, a rear inner connecting rod 2 is fixedly connected to the inward side of the upper side of the rear support frame 1, and a rear outer connecting rod 3 is fixedly connected to the outward side of the upper side of the rear support frame 1. The inner end of the intermediate roller shaft extending from the outer roller sleeve of the rear passive feed roller 5 is connected to the rear inner connecting rod 2 via a bearing, and the outer end of the intermediate roller shaft extending from the outer roller sleeve of the rear passive feed roller 5 is connected to the rear outer connecting rod 3 via a bearing. This allows the connected rear passive feed roller 5 to rotate freely, and a certain distance is maintained between the outer roller sleeve of the connected rear passive feed roller 5 and the upper side of the rear support frame 1. The front active feed roller 6 is supported by the front support frame 4, which is a cuboid structure. The front support frame 4 is inclined downwards and is connected to the rear support frame 1 by a middle connecting plate 23. The middle connecting plate 23 is a cuboid structure. One side of the middle connecting plate 23 is fixedly connected to the rear support frame 1, and the other side is fixedly connected to the front support frame 4. The lower side of the front support frame 4 maintains a certain distance from the ground. The front side of the front support frame 4 is smooth. A front inner connecting rod 21 is fixedly connected to the inward side of the upper side of the front support frame 4, and a front outer connecting rod 22 is fixedly connected to the outward side of the upper side of the front support frame 4. The inner end of the intermediate roller shaft of the front active feed roller 6 extending out of the outer roller sleeve is connected to the front... The inner connecting rods 21 are connected by bearings. The outer end of the intermediate roller shaft of the front active feed roller 6 extending out of the outer roller sleeve is connected to the front outer connecting rod 22 by bearings, so that the front active feed roller 6 can rotate freely after connection. The outer roller sleeve of the front active feed roller 6 after connection is kept at a certain distance from the upper side of the front support frame 4. A conveyor belt 7 is threaded between the rear passive feed roller 5 and the front active feed roller 6. The conveyor belt 7 is a flexible ring material. The conveyor belt 7 passes through the rear passive feed roller 5 and the front active feed roller 6 respectively. The conveyor belt 7 is in a taut state after passing through. The front active feed roller 6 is driven to rotate by the conveyor motor, which in turn drives the conveyor belt 7 to rotate accordingly.
[0025] A continuous combing device is installed at the front of the continuous feeding device.
[0026] The continuous combing device includes a drive roller 8, which is a hollow and closed cylinder. The inward end of the drive roller 8 is fixedly connected to the inner connecting shaft, and the outward end of the drive roller 8 is fixedly connected to the outer connecting shaft. The inner connecting shaft and the inner connecting shaft bracket are connected by bearings, and the outer connecting shaft and the outer connecting shaft bracket are connected by bearings. The drive roller 8 is kept at a certain distance from the ground after connection, so that the drive roller 8 can rotate freely. The inner or outer connecting shaft is driven by the drive roller 8 to rotate via a connecting shaft belt, which in turn drives the drive roller 8 to rotate accordingly.
[0027] A gripping combing device is provided below the side of the driving roller 8, and a free combing device is provided above it. The gripping combing device and the free combing device completely cover the circumference of the side of the driving roller 8.
[0028] The combing device includes a certain number of pressing devices, which are arranged at equal arc intervals along the lower circumference of the side of the drive roller 8 and completely cover the lower circumference of the side of the drive roller 8.
[0029] The pressing device includes an inner pressing arc support 9 and an outer pressing arc support 10 with identical structures. The inner pressing arc support 9 is located on the inward side of the side circumference of the driving roller 8, and the outer pressing arc support 10 is located on the outward side of the side circumference of the driving roller 8. The inner pressing arc support 9 and the outer pressing arc support 10 include an upper pressing arc 11 and a lower pressing arc 12 with identical structures. Both the upper pressing arc 11 and the lower pressing arc 12 are arc-shaped structures. The upper pressing arc 11 and the lower pressing arc 12 are parallel to each other and are also parallel to the side arc of the driving roller 8 directly opposite them. The arc length of the side arc of the driving roller 8 directly opposite the upper pressing arc 11 and the lower pressing arc 12 is less than the main length of the silk fiber being processed. The two ends of the upper pressing arc 11 and the lower pressing arc 12 are fixedly connected by a first pressing arc connecting rod 13 and a second pressing arc connecting rod 14, respectively, thus forming a complete pressing arc support. An opening is made on the downward side of the upper pressing arc 11. The upper connecting groove 15 does not penetrate the thickness of the upper pressing arc 11. A lower connecting groove 16 is opened on the upward-facing side of the lower pressing arc 12. The lower connecting groove 16 does not penetrate the thickness of the lower pressing arc 12. The lower side of the lower pressing arc 12 is fixedly connected to the pressing arc fixing ring through the pressing arc connecting rod. The pressing arc fixing ring is circular. The pressing arc fixing ring of the inner pressing arc bracket 9 is sleeved on the inner connecting shaft and maintains a certain gap with the inner connecting shaft. The inner connecting shaft is fixedly connected to the inner connecting shaft bracket through the inner connecting cylinder, thereby fixing the inner connecting shaft and the inner pressing arc bracket 9. The pressing arc fixing ring of the outer pressing arc bracket 10 is sleeved on the outer connecting shaft and maintains a certain gap with the outer connecting shaft. The outer connecting shaft is fixedly connected to the outer connecting shaft bracket through the outer connecting cylinder, thereby fixing the outer connecting shaft and the outer pressing arc bracket 10.
[0030] An extraction roller is disposed between the inner pressing arc support 9 and the outer pressing arc support 10. The extraction roller includes an extraction roller shaft 17 and an extraction roller sleeve 18. The extraction roller shaft 17 is a solid cylinder made of iron. The extraction roller sleeve 18 is an annular structure made of rubber with a certain degree of soft elasticity. The length of the extraction roller sleeve 18 is less than the length of the extraction roller shaft 17. The extraction roller sleeve 18 is fixedly sleeved on the extraction roller shaft 17, thus forming a complete extraction roller. Both ends of the extraction roller shaft 17 extend outwards from the corresponding ends of the extraction roller sleeve 18, and the lengths of the extensions are the same. An inner embedding groove is formed on the inward-facing end of the extraction roller shaft 17 that extends outwards from the extraction roller sleeve 18. The inner embedding groove surrounds a circumference of the side of the extraction roller shaft 17, thereby allowing the extension of the extraction roller shaft 17... An inner embedded end is formed between the inward end of the extraction roller sleeve 18 and the inner embedded groove. An outer embedded groove is formed on the outward end of the extraction roller shaft 17 extending from the extraction roller sleeve 18. The outer embedded groove surrounds a circumference of the side of the extraction roller shaft 17, so that the outward end of the extraction roller shaft 17 extending from the extraction roller sleeve 18 and the outer embedded groove form an outer embedded end. The inner embedded end of the extraction roller is embedded in the upper connecting groove 15 of the upper pressing arc 11 and the lower connecting groove 16 of the lower pressing arc 12 of the inner pressing arc bracket 9, respectively. The outer embedded end of the extraction roller is embedded in the upper connecting groove 15 of the upper pressing arc 11 and the lower connecting groove 16 of the lower pressing arc 12 of the outer pressing arc bracket 10, thereby realizing the connection of the extraction rollers. After the connection, the extraction roller sleeve 18 of the extraction roller and the driving roller 8 maintain a tight pressing contact.
[0031] Each pressing device has a carding roller 19 located below it. Each carding roller 19 is positioned directly below the corresponding pressing device and is arranged at equal arc intervals along the outer side of the driving roller 8. The distance between each carding roller 19 and the outer side of the driving roller 8 is the same. Each carding roller 19 is driven by a unified transmission mechanism to rotate synchronously counterclockwise or clockwise. The direction of rotation of the carding roller 19 is the same as that of the driving roller 8. A carding needle holding cloth is provided on the outer side of the carding roller 19. The carding needle holding cloth is composed of carding needles. The carding needles are arranged at equal intervals along the length of the outer side of the carding roller 19, thus forming a row of carding needles. Each row of carding needles is arranged at equal arc intervals along the circumference of the outer side of the carding roller 19, thus forming a complete carding needle holding cloth.
[0032] The free carding device includes a certain number of carding plates 20. The carding plates 20 have an arc-shaped structure. The circumference of the arc-shaped carding plates 20 is consistent with the diameter of the side circumference of the driving roller 8. The two ends of the carding plates 20 are fixedly connected to the fixing rings respectively. The fixing rings are fixedly connected to the machine platform. The carding plates 20 are arranged along the side circumference of the driving roller 8 and completely cover the side circumference of the driving roller 8 without gaps. Free carding needle cloth is provided on the side of the carding plates 20 facing the driving roller 8.
[0033] In use, the front active feed roller 6 is driven to rotate by the conveyor motor, which in turn drives the conveyor belt 7 to rotate accordingly. The bar wool to be processed is laid flat on the conveyor belt 7, and then the rotation of the conveyor belt 7 drives the placed silk fibers to be continuously conveyed forward. The conveyed silk fibers are directly transferred to the front support frame 4, and then slide down along the inclined and smooth front support frame 4 to realize the feeding of silk fibers.
[0034] The slipping silk fibers fall between the driving roller 8 and the extraction roller of a corresponding pressing device. At this time, the driving roller 8 is driven by a motor to rotate counterclockwise, which in turn drives the extraction roller in contact with it to rotate clockwise. Under the clockwise rotation, the extraction roller slides along the counterclockwise direction within the upper pressing arc 11 and lower pressing arc 12 of the inner pressing arc support 9 and the outer pressing arc support 10 until the extraction roller slides to the end position of the upper pressing arc 11 and lower pressing arc 12. At this time, the upper pressing arc 11 and lower pressing arc 12 block the extraction roller, so that the extraction roller only enters... As the machine rotates clockwise, the silk fibers sliding down from the front support frame 4 are pressed and fed in between the drive roller 8 and the extraction roller. Driven by the combined rotation of the drive roller 8 and the extraction roller, the fed silk fibers continue to be conveyed forward, causing them to fall continuously. Consequently, the leading edge of the silk fibers along the conveying direction droops under its own gravity. The drooping silk fibers then come into contact with the carding roller 19, allowing the leading edge of the silk fibers, while the rear end is held, to be carded by the carding cloth of the carding roller 19. Under the carding action, the leading edge of the silk fibers... The end hooks are straightened, and simultaneously, driven by the rotation of the drive roller 8, the silk fibers are continuously conveyed forward along the axial direction of the drive roller 8. This allows the silk fibers to sequentially enter each pressing device, where they are gripped and combed by the corresponding combing rollers 19. As the silk fibers transfer between the pressing devices, one end of the shorter silk fibers, after escaping the pressing of the extraction roller and drive roller 8 of the previous pressing device, cannot be pressed by the extraction roller and drive roller 8 of the next pressing device, and thus falls down for removal, achieving the elimination of short fibers. On the other hand, the fed... As the silk fibers fall continuously, the newly fed silk fibers begin to be combed by the combing roller 19 under the grip of the extraction roller of the pressing device; thus achieving front-end combing of the silk fibers. During the front-end combing process, along the length direction of the silk fibers, the front end of the silk fibers falls first and comes into contact with the combing roller 19, thus receiving the most combing action. Subsequently, along the length direction of the silk fibers, from the front end to the rear end, the combing action on the silk fibers gradually decreases. After the roller 8 rotates a certain number of circumferences, the silk fibers complete the full front-end combing process.
[0035] Then, the silk fiber feeding stops, and the driving roller 8, driven by the motor, rotates clockwise at the same speed as during counterclockwise rotation. This, in turn, drives the extraction roller, which is in contact with the roller, to rotate counterclockwise. Under the action of counterclockwise rotation, the extraction roller slides clockwise within the upper pressing arc 11 and lower pressing arc 12 of the inner pressing arc support 9 and the outer pressing arc support 10, until it reaches the endpoints of the upper pressing arc 11 and lower pressing arc 12. At this point, the upper pressing arc 11 and lower pressing arc 12... Arc 12 blocks the extraction roller, causing it to rotate only counterclockwise. Driven by the combined rotation of the drive roller 8 and the extraction roller, the fully combed silk fibers move in the corresponding direction, causing the rear ends of the silk fibers to continuously fall along the silk fiber conveying direction. Subsequently, the rear ends of the silk fibers along the conveying direction droop under their own gravity. The drooping silk fibers then begin to contact the combing roller 19, thus allowing the rear ends of the silk fibers to open while the front ends are held. The silk fibers are initially combed by the carding roller 19. Under the combing action, the hooks at the rear end of the silk fibers are straightened. Driven by the rotation of the drive roller 8, the silk fibers are continuously conveyed forward along the axial direction of the drive roller 8, so that the silk fibers enter each pressing device in sequence and are held and combed with the corresponding carding roller 19. When the silk fibers are transferred between the pressing devices, one end of the shorter silk fibers is released from the pressing of the extraction roller and drive roller 8 of the previous pressing device, and the other end cannot be pressed by the extraction roller and drive roller 8 of the next pressing device, and then falls to be removed, thus eliminating short fibers. Then the rear end of the silk fibers is combed. During the rear end combing process, along the length direction of the silk fibers, the rear end of the silk fibers falls first and comes into contact with the carding roller 19, so that they receive the most combing action. Then, along the length direction of the silk fibers, the combing action received by the silk fibers gradually decreases from the rear end to the front end. After the drive roller 8 rotates a certain number of circumferences, the silk fibers complete the full rear end combing process.
[0036] During the rotation of the drive roller 8, the silk fibers that are driven to the top of the drive roller 8 enter the area between the drive roller 8 and the carding plate 20. In this area, the silk fibers are free and are carded by the free carding needles on the carding plate 20. During this process, the silk fibers are driven by the drive roller 8, which causes the free carding needles to randomly insert between the silk fibers, thereby increasing the separation between the silk fibers. At the same time, when the silk fibers are removed from the free carding needles, the silk fibers that are not fully straightened are further straightened.
[0037] Keep the silk fiber feeding stopped and continue the front and back combing process of the silk fiber for a certain period of time until the required front and back combing process of the silk fiber is completed. When the silk fiber completes the last front or back combing, drive roller 8 continues to rotate counterclockwise or clockwise, so that the silk fiber that has completed the front and back combing is released from the pressing action of drive roller 8 and extraction roller. Then, the combed silk fiber is removed by extraction rod, and then the silk fiber is fed and combed again.
[0038] Step 2: Fiber spinning: The obtained cotton sheet is stretched into a certain length of cotton strip in one pass, and then further connected by sliver making. Through stretching, the fibers are further straightened and parallelized to form a continuous cotton sliver. The cotton sliver is then processed by four drawing passes to obtain a fine cotton sliver with improved silk fiber straightness and weight distribution uniformity. The fine cotton sliver is then roving to produce silk roving with a certain internal friction field. The roving is done on a cotton spinning roving machine with a spindle blade. The silk roving is then spun to produce silk yarn with a certain strength. The spinning is done on a cotton spinning ring spinning machine with a mesh ring compact spinning device.
[0039] Step 3: Plying the single yarn: Two or more silk yarns are combined in parallel to form a large-capacity combined yarn bobbin. The combined yarn bobbin is then twisted to form a ply of two or more parallel silk yarns to form a silk ply. The silk ply is then singed twice to obtain a silk ply suitable for subsequent weaving processing.
[0040] Step 4: Fabric processing: A portion of the silk strands to be woven are warped to obtain a warp beam suitable for weaving. The warp beam and the silk strands to be woven are then woven together to produce a high-density industrial filter fabric. A rapier loom is used in the weaving process, and a plain weave structure is adopted.
[0041] Step 5: Post-processing: Industrial filter fabrics are scourted to remove oils and waxes applied during spinning and weaving; then heat-set under high temperature and tension to fix the fabric and obtain a stable pore structure; then embossing, through mechanical pressure, makes the fabric surface smoother and tighter, further precisely controlling porosity and air permeability; finally, they are cut and sewn to obtain the required industrial filter fabric, with high-strength yarns such as aramid or PTFE yarns selected during sewing.
[0042] The production of silk filaments with a linear density of 120 Nm / 2 and corresponding industrial filter fabrics will be used as an example for illustration.
[0043] (1) Degumming Table 1 Process Parameters
[0044] (2) Bleaching reduction Table 2 Main process parameters for bleaching process
[0045] (3) Moisturize Table 3 Main process parameters of the humidification process
[0046] (4) Mix cotton Table 4 Parameters for cotton blending
[0047] (5) Opening cotton Table 5 Process parameters for cotton opening process
[0048] (6) Cut cotton The cylinder rotation speed is 170 r / min, the cylinder-to-needle roller speed ratio is 35:9, the spacing is 7 mm, and the weight of the semi-finished rod is 30 g.
[0049] (7) Carding The drive roller rotates at 50 r / min, the carding roller rotates at 128 r / min, and the gap between the carding plate and the drive roller is 1.2 mm.
[0050] (8) Extension and merging Table 6. Strip Forming Process Parameters
[0051] (9) Corrugated yarn Table 7 Roving process parameters
[0052] (10) Fine yarn Table 8. Fine yarn process parameters
[0053] (11) Twin silk A tension sheet weighing 6 g was selected to stabilize the tension.
[0054] (12) Twisting silk It adopts a Z-twist with the opposite twist direction to that of single yarn, and the designed twist is 500T / m.
[0055] (13) Singeing Table 9 Main process parameters for singeing
[0056] (14) Weaving Heavy-duty rapier looms are used, with a warp density of 490 ends / 10cm and a weft density of 470 ends / 10cm. The total tightness is controlled at over 90%, and high-tension weaving is employed.
[0057] (15) Yarn quality test Table 10 Single Yarn Strength and Elongation
[0058] Table 11 Single Yarn Hairiness
[0059] Table 12 Single Yarn Evenness
[0060] Table 13 Strength of the Thread
[0061] Table 14 shows the fuzziness after singeing 14 strands of thread.
[0062] (16) Fabric quality testing
[0063] The above description, based on the embodiments shown in the figures, details the structure, features, and effects of the present invention. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, that do not exceed the spirit covered by the specification and figures, should be within the protection scope of the present invention.
Claims
1. A highly efficient production method for industrial filter fabrics, characterized in that, Includes the following steps: Step 1: Fiber sheet formation: Silk fibers are refined into clean, dry cotton through processes including degumming, bleaching and reduction, and humidification; then, through blending, opening, and cutting, they are made into bar cotton suitable for carding; finally, cotton sheets are obtained through a high-efficiency carding machine including a continuous feeding device and a continuous carding device. The continuous feeding device includes a rear passive feeding roller and a front active feeding roller, which are rotatably supported by rear and front support frames, and a conveyor belt is wrapped around the two. The continuous carding device includes a drive roller, with a gripping carding device located below its side and a free carding device located above it, both of which fully cover the circumference of the side of the drive roller. The holding and combing device includes a pressing device that fully covers the lower circumference of the side of the driving roller. The pressing device includes identical inner and outer pressing arc supports. Between the two is an extraction roller that slides along the inner and outer pressing arc supports and rotates along its own axis. A combing roller is set directly below each mounting device, and a holding and combing needle cloth is set on it. The free carding device includes a carding plate that completely covers the upper circumference of the side of the drive roller without any gaps, and a free carding needle cloth is arranged on the side facing the drive roller; The fiber is continuously fed into the conveyor belt, and the roller rotates counterclockwise during the feeding process. The fiber enters between the roller and the pressing device. Under the pressing and pulling of the roller and the extraction roller, the fiber is straightened and combed at the front end in the pressing device. Then the feeding stops and the roller rotates clockwise. Under the pressure of the roller and the extraction roller, the rear end straightens and combs within the pressing device. During the straightening and combing process at both the front and rear ends, the fiber is transferred between various installation devices under the drive of the drive roller; During the straightening and carding process, the fibers that are driven to the top of the drive roller enter between the drive roller and the carding plate. The fibers are driven by the drive roller, causing the free carding needle cloth to be randomly inserted between the fibers, improving the separation between the fibers. When the fibers are removed from the free carding needle cloth, the fibers that are not fully straightened are further straightened. Keep the fiber feeding stopped and straighten and comb the front and back ends for a certain period of time, then remove the combed silk fibers by the extraction rod; Step 2: Fiber spinning: The cotton sheet is stretched into a certain length of cotton strip in one pass, and then further connected and stretched into a continuous cotton sliver through sliver making; it is then finished by four passes of drawing to obtain a fine cotton sliver; it is then processed by a roving machine of cotton spinning to obtain silk roving; and it is then processed by a ring spinning machine of cotton spinning with added mesh rings to obtain silk yarn. Step 3: Plying the single yarn: Two or more silk yarns are combined and twisted to make silk ply yarn, which is then singed twice to make silk ply yarn ready to be woven. Step 4: Fabric processing: A portion of the silk filaments to be woven are warped to form a warp beam, and the warp beam and the silk filaments to be woven are then woven to produce a high-density industrial filter fabric. Step 5: Post-processing: After refining and heat setting to obtain a stable pore structure, the pores are further precisely controlled by embossing, and then the industrial filter fabric is produced by cutting and sewing.
2. The efficient production method of industrial filter fabric according to claim 1, characterized in that, Rapier looms are used in the weaving process, and a plain weave structure is adopted.
3. The efficient production method of industrial filter fabric according to claim 1, characterized in that, The rear passive feed roller and the front active feed roller include an intermediate roller shaft and an outer roller sleeve. The intermediate roller shaft is a solid cylindrical structure made of steel. The outer roller sleeve is an annular structure made of hard rubber. The inner diameter of the outer roller sleeve is the same as the outer diameter of the intermediate roller shaft. The length of the outer roller sleeve is less than the length of the intermediate roller shaft. The outer roller sleeve is fixedly fitted onto the intermediate roller shaft, and the two ends of the outer roller sleeve after being fitted maintain a certain and equal distance from the two ends of the corresponding intermediate roller shaft. The rear passive feed roller is supported by a rear support frame, which is a cuboid structure and is set vertically on the ground. An inner rear connecting rod is fixedly connected to the inward side of the upper side of the rear support frame, and an outer rear connecting rod is fixedly connected to the outward side of the upper side of the rear support frame. The inner end of the intermediate roller shaft of the rear passive feed roller extending out of the outer roller sleeve is connected to the inner rear connecting rod by a bearing, and the outer end of the intermediate roller shaft of the rear passive feed roller extending out of the outer roller sleeve is connected to the outer rear connecting rod by a bearing. A certain distance is maintained between the outer roller sleeve of the rear passive feed roller and the upper side of the rear support frame after the connection. The front active feed roller is supported by a front support frame, which is a cuboid structure and is set in a downward inclined state. The front support frame and the rear support frame are connected to each other by a middle connecting plate, which is also a cuboid structure. One side of the middle connecting plate is fixedly connected to the rear support frame, and the other side is fixedly connected to the front support frame. The lower side of the front support frame maintains a certain distance from the ground. The front side of the front support frame is smooth. A front inner connecting rod is fixedly connected to the inward side of the upper side of the front support frame, and a front outer connecting rod is fixedly connected to the outward side of the upper side of the front support frame. The inner end of the intermediate roller shaft of the front active feed roller extending out of the outer roller sleeve is connected to the front inner connecting rod by a bearing, and the outer end of the intermediate roller shaft of the front active feed roller extending out of the outer roller sleeve is connected to the front outer connecting rod by a bearing. After connection, the outer roller sleeve of the front active feed roller maintains a certain distance from the upper side of the front support frame. A conveyor belt is threaded between the rear passive feed roller and the front active feed roller. The conveyor belt is a flexible ring. The conveyor belt passes through the rear passive feed roller and the front active feed roller respectively, and the conveyor belt is in a taut state after being threaded. The front active feed roller is driven to rotate by a conveyor motor.
4. The efficient production method of industrial filter fabric according to claim 1, characterized in that, The pressing device includes an inner pressing arc support and an outer pressing arc support with identical structures; The inner pressing arc support is located on the inward side of the side circumference of the driving roller, and the outer pressing arc support is located on the outward side of the side circumference of the driving roller. The inner pressing arc support and the outer pressing arc support include an upper pressing arc and a lower pressing arc with the same structure. Both the upper pressing arc and the lower pressing arc are arc-shaped structures. The upper pressing arc and the lower pressing arc are parallel and parallel to the side arc of the driving roller directly opposite to them. The arc length of the side arc of the driving roller directly opposite to the upper pressing arc and the lower pressing arc is less than the main body length of the silk fiber being processed. The two ends of the upper pressing arc and the lower pressing arc are fixedly connected by the first pressing arc connecting rod and the second pressing arc connecting rod, respectively. An upper connecting groove is opened on the downward side of the upper pressing arc. The upper connecting groove does not penetrate the thickness of the upper pressing arc. A lower connecting groove is opened on the upward side of the lower pressing arc. The lower connecting groove does not penetrate the thickness of the lower pressing arc. The lower side of the lower pressing arc is fixedly connected to the pressing arc fixing ring through the pressing arc connecting rod. The pressing arc fixing ring is a circular ring. The pressing arc fixing ring of the inner pressing arc bracket is sleeved on the inner connecting shaft, and a certain gap is maintained between the inner connecting shaft and the inner connecting shaft. The inner connecting shaft is fixedly connected to the inner connecting shaft bracket through the inner connecting cylinder. The pressing arc fixing ring of the outer pressing arc bracket is sleeved on the outer connecting shaft, and a certain gap is maintained between the outer connecting shaft and the outer connecting shaft. The outer connecting shaft is fixedly connected to the outer connecting shaft bracket through the outer connecting cylinder.
5. The efficient production method of industrial filter fabric according to claim 4, characterized in that, An extraction roller is installed between the inner and outer pressing arc supports. The extraction roller includes an extraction roller shaft and an extraction roller sleeve. The extraction roller shaft is a solid cylinder made of iron. The extraction roller sleeve is a ring-shaped structure made of rubber with a certain degree of soft elasticity. The length of the extraction roller sleeve is less than the length of the extraction roller shaft. The extraction roller sleeve is fixedly fitted onto the extraction roller shaft, with both ends of the extraction roller shaft extending out of the corresponding ends of the extraction roller sleeve, and the extension lengths at both ends are equal. An inner embedding groove is formed on the inward-facing end of the extraction roller shaft that extends out of the extraction roller sleeve, and the inner embedding groove surrounds the side of the extraction roller shaft. The inner end of the extraction roller shaft extending from the extraction roller sleeve and facing inward forms an inner embedding end with the inner embedding groove. An outer embedding groove is opened on the outer end of the extraction roller shaft extending from the extraction roller sleeve. The outer embedding groove surrounds a circumference of the side of the extraction roller shaft. The outer embedding end of the extraction roller shaft extending from the extraction roller sleeve and facing outward forms an outer embedding end with the outer embedding groove. The inner embedding end of the extraction roller is respectively embedded in the upper connecting groove of the upper pressing arc and the lower connecting groove of the lower pressing arc of the inner pressing arc bracket. The outer embedding end of the extraction roller is respectively embedded in the upper connecting groove of the upper pressing arc and the lower connecting groove of the lower pressing arc of the outer pressing arc bracket.
6. The efficient production method of industrial filter fabric according to claim 5, characterized in that, After connection, the extraction roller sleeve of the extraction roller and the drive roller maintain a tight pressing contact.
7. The efficient production method of industrial filter fabric according to claim 6, characterized in that, Each pressing device has a carding roller installed at its lower part. Each carding roller is located directly below the corresponding mounting device and is arranged at equal arc intervals along the outer side of the driving roller. The distance between each carding roller and the outer side of the driving roller is the same. Each carding roller is driven by a unified transmission mechanism to rotate synchronously counterclockwise or clockwise. The direction of rotation of the carding roller is the same as that of the driving roller. A carding needle holding cloth is provided on the outer side of the carding roller. The carding needle holding cloth is composed of carding needles. The carding needles are arranged at equal intervals along the length of the outer side of the carding roller to form rows of carding needles. Each row of carding needles is arranged at equal arc intervals along the circumference of the outer side of the carding roller to form a complete carding needle holding cloth.
8. The efficient production method of industrial filter fabric according to claim 1, characterized in that, The free carding device includes a certain number of carding plates. The carding plates have an arc-shaped structure. The circumference of the arc-shaped carding plate is consistent with the diameter of the side circumference of the driving roller. The two ends of the carding plate are fixedly connected to the fixing rings respectively. The fixing rings are fixedly connected to the machine platform. The carding plates are arranged along the side circumference of the driving roller and completely cover the side circumference of the driving roller without gaps. Free carding needles are provided on the side of the carding plate facing the driving roller.
9. The efficient production method of an industrial filter fabric according to claim 1, characterized in that, Use high-strength aramid or PTFE thread when sewing.