Crimped Multifilament Thread Knot Pattern Control
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Solution Overview
Problem
The production of crimped multifilament threads for carpet manufacturing faces challenges in achieving reproducible and uniform intertwined knots, leading to irregularities in knot stability and spacing, which affects the visual appearance of carpet products, especially in multi-colored threads.
Innovation Solution
A method and device that utilize a pulse sequence of compressed air pulses directed at the thread at a predetermined frequency to create a reproducible pattern of intertwined knots, with the frequency adjusted based on thread speed to produce a consistent number of knots per unit length, and a rotating nozzle ring with strategically placed nozzle bores to generate pressure pulses, reducing air consumption and allowing for varying patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a continuous stream of compressed air is directed at the thread to generate intertwined knots, then the knots are formed on the thread, but the number of knots per unit length and knot stability are not reproducible due to thread vibrations
Solution Approach 1:
The patent applies periodic action by using a pulsed compressed air treatment instead of continuous air flow. The treatment channel is supplied with compressed air in periodic pulses synchronized with the thread movement, creating reproducible knot formation at regular intervals. This periodic pulsing overcomes the vibration-induced irregularities of continuous air flow and ensures consistent knot spacing and stability.
2Productivity
If compressed air pressure is increased to improve knot formation, then more knots are formed, but the fluctuations in knot stability and number of knots per unit length increase
Solution Approach 1:
The patent uses periodic compressed air pulses with controlled duration and frequency to achieve consistent knot formation. By regulating the pulse timing and duration rather than continuously increasing pressure, the system produces a predetermined number of knots per unit length with consistent spacing, avoiding the fluctuations that occur with continuous high-pressure air flow.
3Productivity
If the thread speed is increased to improve productivity, then more thread is processed, but the knot formation becomes less reproducible
Solution Approach 1:
The patent synchronizes the periodic compressed air pulses with the thread speed to maintain reproducible knot formation at higher processing speeds. The pulse frequency and timing are adjusted in coordination with thread movement, ensuring that regardless of the thread speed, knots are formed at consistent intervals with predictable spacing and stability.
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 ensures a consistent and uniform formation of intertwined knots, enabling the creation of desired patterns in carpet products, improving the visual appearance and processing efficiency of multifilament threads, particularly at high thread speeds.
Implementation Method 1
a pulse sequence of compressed air pulses is directed at the thread at a predetermined frequency
Implementation Method 2
a continuous stream of compressed air is directed crosswise to the thread
Implementation Method 3
a rotating nozzle ring with strategically placed nozzle bores to generate pressure pulses
Implementation Method 4
generate pressure pulses, reducing air consumption
Data Source
AI summary
A method and a device for producing a crimped multifilament thread are described. A multiplicity of filaments are extruded by means of a spinning machine, cooled and subsequently treated by a drawing device and a crimping device to form a crimped thread. Before the thread is wound up to form a bobbin, a multiplicity of intertwining knots is produced on the crimped thread by a treatment device. In order to obtain defined patterns of the intertwining knots within the thread, a pulse sequence of compressed air pulses at a predefined frequency is directed at the thread. The treatment device has a controllable blowing means.