Composite Yarn Production via Carding and Gluing
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Solution Overview
Problem
Existing methods for producing composite yarns with a woven structure face challenges such as irregular Denier quality, loss of parallelism, and difficulty in cutting operations, which complicates subsequent weaving processes and energy consumption.
Innovation Solution
A method involving the integration of cotton fibrils and yarns through a carding process, followed by pre-gluing, pre-drying, complete gluing, and progressive drying to achieve a composite yarn with an untwisted cotton sheath, ensuring parallelism and enhanced Denier quality, using a specific installation that includes a confluence collection cylinder, pressing cylinders, and drying cylinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a woven structure is used to produce composite yarns, then the structural stability is improved, but the energy consumption and manufacturing complexity increase
Solution Approach 1:
The patent extracts and eliminates the woven structure from the composite yarn production process. Instead of creating a woven structure and then cutting it, the invention directly produces individual composite yarns by integrating cotton fibrils with carrier yarns in a non-woven configuration, thereby removing the unnecessary energy-consuming weaving and cutting operations while maintaining structural stability through the fibril-yarn integration
Solution Approach 2:
The patent applies preliminary action by integrating cotton fibrils with carrier yarns during the carding process itself, rather than weaving them separately and then cutting. The carding machine performs the integration function in advance, creating the final composite yarn structure directly without requiring subsequent weaving and cutting operations, thus reducing energy consumption
2Manufacturing precision
If cotton fibres are not directed perpendicular to yarns, then the parallelism between yarns is maintained, but the cutting operation becomes difficult and slow
Solution Approach 1:
The patent extracts and eliminates the cutting operation entirely from the production process. By integrating cotton fibrils with carrier yarns during carding to form complete composite yarns directly, the invention removes the need for subsequent cutting operations, thereby resolving the contradiction between maintaining parallelism and achieving high cutting speed - the cutting step is simply not performed
3Ease of manufacture
If a flat ribbon structure is produced, then the manufacturing simplicity is improved, but the applicability to weaving operations deteriorates
Solution Approach 1:
The patent changes the structural parameters of the output from a flat ribbon to individual composite yarns with integrated cotton fibrils. This parameter change allows the product to be directly applicable to weaving operations while maintaining manufacturing simplicity, as the carding machine produces the final composite yarn structure in one continuous process without requiring subsequent ribbon formation or cutting operations
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 method produces a cost-effective, environmentally friendly composite yarn with improved Denier quality and parallelism, facilitating easier cutting and weaving operations while reducing energy consumption and tree cutting.
Implementation Method 1
cotton fibrils having passed through a card in order to form a first initial cotton lap
Implementation Method 2
the lap formed by yarns and cotton fibrils is subjected to a pre-gluing phase, being previously pressed by two cylinders in order to remove all the air contained into the tubular structure of cotton fibrils
Implementation Method 3
the structure of cotton fibrils and yarns is slightly dipped into a vat containing water and glue with low viscosity
Implementation Method 4
Following the complete gluing phase there is a progressive drying phase from low to high temperature developed through a series of hot cylinders
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to the entire method for arranging parallel yarns from a warp on a cotton lap having passed through a card or a combing machine or other textile machine used for the same purpose, forming a composite lap of parallel yarns and a lap of irregularly arranged untwisted cotton fibrils. The end result is a firm lap in which many of the untwisted cotton fibrils are wrapped coaxially around each so-called carrier yarn, forming the corresponding composite yarn, and the remaining fibrils are perpendicular to the composite yarns, providing the resulting lap with a consistency such that it can both be cut to obtain the yarns comprising an untwisted cotton sheath, and also used for any desired purpose.