Carding Element With Pressure Channel For Thermal Deformation Control
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Solution Overview
Problem
Current carding elements made of extruded aluminum profiles deform due to thermal gradients during the carding process, leading to a non-constant carding gap and reduced carding quality, especially as the working width increases, causing fibers to accumulate outside the working width and affecting nep resolution.
Innovation Solution
A carding element design with a support body and a head area featuring a channel that allows for internal pressure adjustment, enabling the carding element to bend and maintain a constant carding gap, using an adjusting element such as a threaded rod or knurled screw to apply pressure, allowing for easy adjustment during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum extruded profiles are used as support components, then weight is reduced and rigidity is increased, but thermal deformation occurs leading to inconsistent carding gap
Solution Approach 1:
The patent applies thermal expansion compensation by designing the support component to account for thermal deformation parameters. The component is pre-configured with compensation mechanisms that adjust for the expected thermal expansion when heated from 20°C to 45°C, maintaining carding gap consistency despite temperature changes during the carding process.
2Productivity
If working width is increased, then productivity is improved, but thermal gradients cause greater deformation and uneven carding gap
Solution Approach 1:
The support component is divided into multiple heating zones corresponding to different sections of the carding element. Each zone can be heated independently or with different temperatures, allowing compensation for thermal gradients across the working width. This segmentation enables precise control of thermal deformation in each region, maintaining uniform carding gap even at larger working widths.
3Shape
If tension rod is used to compress carding element, then hollow contour is achieved, but adjustment during operation becomes difficult
Solution Approach 1:
The support component incorporates adjustable elements that allow dynamic modification of the hollow contour during operation. The component can be adjusted between different contour configurations to adapt to varying carding requirements, maintaining both the hollow contour shape and operational flexibility.
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
The design allows for precise adjustment of the carding element's contour, maintaining a consistent carding gap over the entire working width, improving carding quality and preventing fiber accumulation, even at larger working widths.
Implementation Method 1
The necessary temperature gradient within the profile cross-section leads to the deformation of the fixed carding element
Implementation Method 2
Heating not only causes thermal expansion across the entire working width of the card
Implementation Method 3
Within the at least one channel, pressure can be exerted on the head region of the carding element, causing the carding element to bend
Data Source
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AI summary
The present invention relates to a carding element (20) with a supporting body (20b), it being possible to fasten a fitting to the foot region (20a) of said supporting body, wherein a head region (20e) is arranged in a manner distanced from the foot region (20c) by at least one back part (20a). The invention is characterised in that the head region (20e) has at least one channel (20f) which extends at least partially over the length of the carding element (20), wherein in the channel (20f) a pressure on the head region (20e) of the carding element (20) can be generated. The invention further relates to a card or carding machine.