Buckled Crimp Yarn Cake Formation Without High-Speed Winding
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Solution Overview
Problem
Conventional methods for producing buckled crimp yarn require high-speed winders, leading to high costs and safety concerns, and result in flat yarn that can revert to its original structure, making it difficult to achieve both compactness and bulkiness in fiber packages.
Innovation Solution
A method involving extruding a fiber forming fluid into a pressurized gas chamber, forming a buckled crimp fiber rod, and compressing it into a cake without high-speed rotating bodies, using a compressing chamber with reverse funnel and hollow cylindrical sections to create a releasable buckled crimp yarn cake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high-speed winder is used to spin fiber at 5,000 m/min or more, then productivity is improved, but device complexity and safety requirements increase significantly
Solution Approach 1:
The invention extracts the high-speed spinning function from the traditional winder system and implements it through a pressurized gas chamber that propels fibers at high speed without requiring complex mechanical winding mechanisms. The gas chamber directly accelerates fibers from the spinneret to forming speeds of 5,000 m/min or more, eliminating the need for high-speed rotating winders and their associated safety and complexity issues.
Solution Approach 2:
The invention replaces the mechanical winder system with a pneumatic system using pressurized gas to achieve high-speed fiber transport and forming. Instead of mechanical rotation and tensioning, compressed gas provides the driving force, substituting complex mechanical components with a simpler pneumatic mechanism that achieves the same productivity goals.
2Shape
If crimping process is interposed after high-speed winding, then buckled crimp yarn is obtained, but significant speed reduction is unavoidable
Solution Approach 1:
The invention merges the high-speed spinning process with the crimping process into a single integrated operation. The pressurized gas chamber simultaneously performs fiber acceleration, buckling, and crimping in one continuous motion, eliminating the need for separate crimping steps that would require speed reduction. The crimp structure is formed during the high-speed propulsion itself, maintaining productivity while achieving the desired shape.
3Shape
If crimping processing is performed separately on flat yarn, then buckled crimp yarn is obtained, but rewinding is required which increases costs
Solution Approach 1:
The invention combines spinning and crimping into a single integrated process that occurs continuously within the pressurized gas chamber. The fiber is spun and crimped in one uninterrupted operation, eliminating the need for separate crimping steps and the associated rewinding operations. This integration reduces manufacturing complexity and costs while maintaining the desired crimp structure.
4Ease of manufacture
If fiber is extruded into atmosphere without buckled crimp process, then simple process is achieved, but crimping property of resulting fiber is not high
Solution Approach 1:
The invention uses pressurized gas to create a controlled pneumatic environment that enables both simple process operation and high crimp property. The pressurized gas chamber provides a uniform high-speed flow field that naturally buckles and crimps fibers as they are propelled through the chamber. This pneumatic mechanism achieves effective crimping without complex mechanical components, maintaining process simplicity while improving crimp properties.
5Quantity of substance
If buckled crimp fiber rod is made into spirally stored package, then packaging is achieved, but package is easy to collapse and density cannot be made high
Solution Approach 1:
The invention applies excessive compressive force during the gas-propulsion process, forcing fibers into a densely packed configuration as they exit the pressurized chamber. The high-velocity gas stream and subsequent deceleration create natural compression that achieves high package density without requiring separate compression steps. The resulting package structure is stable and resistant to collapse due to the dense fiber arrangement.
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
Enables safe, cost-effective production of a highly crimped and bulky yarn cake suitable for small-lot, high-mix production, with excellent dimensional stability and no need for rewinding, while maintaining fiber versatility.
Implementation Method 1
a pressurized gas chamber (3), and a narrow hole (6) positioned opposite to the spinneret (1). The fiber (2) extruded from the spinneret (1) is picked up together with a high-speed fluid and solidified
Implementation Method 2
The fiber (2) extruded from the spinneret (1) is picked up together with a high-speed fluid and solidified
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
[Summary] The present invention provides a compact package of buckled crimp yarn having high bulkiness, an inexpensive and safe manufacturing method thereof, and a manufacturing apparatus therefor. That is, it is possible to produce a releasable buckled crimp fiber cake from a high-speed extruded fiber using simple equipment without winding. Since buckled crimp is imparted to said spinning fiber at the same time as solidification, a robust and bulky crimp is imparted. Moreover, since the fiber is compressed into a cake shape in a filament-opened state, compactness of packages and bulkiness of the opened filaments are achieved all at once. Meanwhile, in a traditional buckled crimp imparting method, the crystal structure of a fiber once fixed in a flat yarn state tends to remain, and it is difficult to improve its bulkiness and fastness. Since a winder is not used in the present invention, the equipment is simple, and it is easy to produce many kinds of product in small quantities. Further, in the package according to the present invention, since fibers are laminated in a columnar shape and can be divided along the lamination surface at an arbitrary portion, there is no need for rewinding for subdividing the package. Incidentally, although flat yarn cannot be obtained by the method of the present invention, the versatility of the resulting fiber is not impaired due to the fact that it is inherently crimped, as is the case with wool and cotton yarn. [Problems] With conventional technology, obtaining buckled crimp yarn from a spinning raw material required tedious processes such as spinning, winding, unwinding, buckled crimp processing, and rewinding. In other words, winding requires a high-speed winder and an associated automatic package switching device, and it was not easy to create an inexpensive and safe facility, or to create a facility that is flexible enough to be suitable for small-lot, high-mix production. Moreover, a fiber that has been drawn using rollers goes through a process where it is temporarily fixed as flat yarn. Therefore, even if it is later buckled crimped, the resultant final product is likely to revert to a crystalline structure that was created on the way of the process, making it difficult to obtain a fiber with a robust buckled crimp in terms of yarn quality. Furthermore, with conventional spool-type packages, it is difficult to achieve both compactness of packages and bulkiness of released yarn. [Solution] A fiber-forming fluid is extruded from a spinneret and ejected with a pressurized gas through a narrow hole positioned opposite to the spinneret; and the resultant fiber is made into a rod of fiber having a buckled crimp in a crimping zone provided at the end of said narrow hole; and the rod of fiber is sent and accumulated into a compressing chamber comprising a reverse funnel-like section and a hollow cylindrical section, and a releasable buckled crimp yarn cake is produced by vibrational compression from the downstream side of said compressing chamber.