Air-Permeable Tubular Yarn Containers for Faster Changeovers
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Solution Overview
Problem
Changing the color or design of greige fabric in tufting processes requires labor-intensive and time-consuming replacement of numerous yarn cones, which is inefficient.
Innovation Solution
A yarn storage system with tubular containers that allow non-wound yarns to be stored and filled using compressed fluid, featuring an air-permeable wall and controlled air flow to maintain consistent yarn tension, enabling easy and organized yarn supply to textile machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If yarn cones are stored in traditional racks for tufting machines, then yarn supply is available, but changeover time increases and labor intensity increases when changing color or design
Solution Approach 1:
The invention divides the yarn storage system into modular tubular containers, each holding a single yarn in non-wound form. These containers can be independently replaced or refilled, allowing rapid changeover between different yarn colors or types without replacing entire racks of cones. The segmented design enables selective replacement of only the containers needing change.
Solution Approach 2:
The invention uses compressed air to blow yarn into the tubular containers and to facilitate yarn removal during consumption. The air flow system automatically fills containers with yarn in non-wound form and enables controlled yarn extraction, reducing manual labor and accelerating the changeover process when different yarns need to be installed.
2Quantity of substance
If multiple yarn cones are stored in racks, then sufficient yarn supply is provided, but the number of components increases and handling complexity increases
Solution Approach 1:
The invention consolidates multiple yarn cones into a single tubular container by storing yarn in non-wound form. Multiple containers can be arranged in a simplified rack structure, but each container holds the equivalent of many cones worth of yarn. This merging reduces the total number of individual components (cones and their holders) while maintaining sufficient yarn capacity.
Solution Approach 2:
The invention transitions from storing yarn in the traditional conical wound form to a linear non-wound configuration within tubular containers. This dimensional change from 3D wound cones to 1D linear yarn storage within tubes simplifies the overall system structure, reduces component count, and enables more efficient space utilization in the storage rack.
3Stability of the object's composition
If yarn is wound on cones, then yarn is organized for storage, but yarn tension varies during removal and handling
Solution Approach 1:
Instead of winding yarn into cones and unwinding during use, the invention inverts the approach by storing yarn in non-wound linear form within tubular containers and allowing yarn to be fed out in a controlled manner. This inversion eliminates the tension variations inherent in unwinding from cones, as the yarn is simply pulled through the container rather than unwound from a wound structure.
Solution Approach 2:
Compressed air is used to blow yarn into the tubular containers during filling and to facilitate controlled yarn removal during consumption. The pneumatic system ensures uniform yarn packing during storage and provides consistent, controlled yarn feed during use, maintaining stable yarn tension throughout the process without the variability associated with traditional cone unwinding.
4Ease of manufacture
If traditional yarn cones are used, then yarn storage is simple, but yarn waste increases during changeover and handling
Solution Approach 1:
The invention prepares yarn in non-wound form and loads it into tubular containers in advance, with the yarn end positioned for immediate consumption. This preliminary preparation eliminates the need for trimming and waste generation that occurs during traditional cone changeover, as the yarn is already in the correct configuration and position for use, reducing both handling complexity and material waste.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces changeover time and yarn waste by allowing efficient, tension-controlled yarn supply to tufting machines and other textile equipment, minimizing the need for multiple spools and optimizing yarn usage.
Implementation Method 1
The working principle of the yarn storage system according to the invention is based upon the fact that such tubular containers can be filed with yarn by blowing yarn into the tube, e.g. by means of compressed fluid, such as air
Implementation Method 2
said tubular wall is air permeable by means of a plurality of openings present along the axial length of said tubular container
Implementation Method 3
providing a laminar air stream in axial direction from the first axial extremity to the second axial extremity along the walls of the tubular container
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
A yarn storage container for storing a yarn, said storage container comprising a tubular container, having an axial length, a tubular wall and a first and second axial extremity, the first axial extremity of said tubular container having an opening for receiving an end of a yarn, said second axial extremity of said tubular container being air-permeably closed, said tubular wall is air permeable by means of a plurality of openings present along the axial length of said tubular container.