Rotating Cooling Drum with Zoned Gas Streams for Yarn Texturing
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Solution Overview
Problem
Existing texturing devices for manufacturing crimped synthetic yarns often result in significant internal differences in yarn quality due to interference between yarn plugs during the cooling process, leading to filament breakage, uneven cooling, and reduced yarn smoothness.
Innovation Solution
A device and method that utilize a rotating cooling drum with distinct zones, where a gas stream is generated in the second zone to keep yarn plugs in place, and no or less powerful gas stream is used in the intermediate zone to prevent interference, ensuring consistent cooling and reducing the risk of filament entanglement and breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If yarn plugs are placed close together on the cooling drum to increase production capacity, then productivity is improved, but interference between yarn plugs occurs leading to filament entanglement and quality deterioration
Solution Approach 1:
The cooling drum surface is segmented into multiple zones with different gas stream characteristics. The first zone has no gas stream or less powerful gas stream to prevent interference between yarn plugs, while the second zone has a gas stream to keep yarn plugs in place. This spatial segmentation allows yarn plugs to be placed closer together without causing entanglement, thereby increasing productivity while maintaining quality uniformity.
Solution Approach 2:
Different regions of the cooling drum surface are assigned different local qualities in terms of gas stream intensity. The first zone (where yarn plugs are initially placed) has reduced or no gas stream to minimize interference, while the second zone (where yarn plugs are later moved) has a gas stream to maintain their position. This local differentiation resolves the contradiction by allowing high density placement without uniform interference across the entire surface.
2Stability of the object's composition
If gas stream is applied uniformly across the cooling drum surface to keep yarn plugs in place, then yarn plug stability is improved, but interference between yarn plugs in different zones occurs leading to filament breakage
Solution Approach 1:
The gas stream application is segmented into different zones: the first zone has no gas stream or less powerful gas stream to prevent harmful interference and filament breakage, while the second zone has a gas stream to maintain yarn plug stability. This zoned approach allows stability to be achieved where needed without causing the harmful effects that would result from uniform gas stream application.
Solution Approach 2:
The gas stream intensity is varied locally across the cooling drum surface. In the first zone, reduced or absent gas stream prevents filament breakage and entanglement by minimizing interference between yarn plugs. In the second zone, the gas stream provides the necessary stability to keep yarn plugs in place. This local quality differentiation resolves the contradiction between stability and harmful effects.
3Device complexity
If yarn plugs are placed in a single continuous zone on the cooling drum, then device complexity is reduced, but interference between yarn plugs from different turns occurs leading to quality differences
Solution Approach 1:
The cooling drum surface is divided into multiple zones (first zone and second zone) with different gas stream characteristics. This segmentation prevents interference between yarn plugs from different turns by providing a transition region where yarn plugs can be laterally moved without causing quality differences, while maintaining relatively simple device structure.
Solution Approach 2:
Different zones of the cooling drum surface are assigned different local qualities in terms of gas stream intensity. The first zone has reduced or no gas stream to minimize interference, while the second zone has a gas stream to maintain position stability. This local differentiation allows yarn quality consistency to be achieved without significantly increasing device complexity.
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
This approach significantly reduces the risk of internal differences in yarn quality by maintaining yarn plugs in the second zone and preventing interference, resulting in more uniform crimped synthetic yarns with improved smoothness and reduced filament damage.
Implementation Method 1
a cooling surface for cooling the yarn plugs supplied from the texturing unit
Implementation Method 2
gas stream means provided to generate a gas stream to keep yarn plugs on the cooling surface
Data Source
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AI summary
The present invention relates to a device and a method for manufacturing a synthetic yarn, in which at least two yarn plugs (1), (2), (3) are produced by texturing, are placed in a first zone (A) on the cooling surface (6c) of a rotating cooling drum (6), moved to a second zone (B) and form more than one winding (I),(II), in which the yarn plugs are kept in the second zone (B) by a gas stream (FB) on the cooling surface (6c), and in which no gas stream or a less powerful gas stream is generated in an intermediate zone (C) in order to prevent the yarn plugs (1), (2), (3) from leaving the second zone (B).