Crosswound Textile Bobbin Edge Stabilization
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Solution Overview
Problem
Existing textile bobbins experience significant thread waste and instability in the end area of winding due to increased crossing angles, leading to mechanical stress and yarn cuts during transport and handling.
Innovation Solution
The solution involves shifting the reversal points of the winding towards the end face of the coil without increasing the crossing angle, achieved through a beveled edge design or gradual reduction in winding width, which reduces mechanical stress and prevents yarn cuts without affecting package density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the crossing angle is increased to reduce thread knock-offs, then thread waste is reduced, but package density is reduced and thread layers become unstable
Solution Approach 1:
The patent applies preliminary action by pre-shaping the bobbin with a specific geometric configuration (rounded end faces or tapered design) before winding begins. This pre-configured bobbin shape guides the thread layers to naturally form stable edges without requiring increased crossing angles, thereby maintaining package density while preventing thread knock-offs during transport and handling.
Solution Approach 2:
The patent changes the geometric parameters of the bobbin itself (end face curvature radius, taper angle) rather than changing the winding parameters (crossing angle). This parameter change in the bobbin structure allows the thread layers to be stabilized at the edges through the bobbin's shape, maintaining both high package density and thread stability without the need to increase the crossing angle.
2Reliability
If the crossing angle is increased to prevent yarn cuts, then mechanical stress is reduced, but energetic and mechanical load on the thread guide increases
Solution Approach 1:
The bobbin is pre-configured with specific geometric features (rounded end faces or tapered shape) that guide the thread layers to form stable edges during winding. This preliminary structural preparation reduces the need for high crossing angles, thereby reducing the mechanical load and energetic requirements on the thread guide while still preventing yarn cuts through proper layer stabilization.
Solution Approach 2:
The patent changes the bobbin's geometric parameters (end face curvature, taper angle) to create a structure that naturally stabilizes thread layers. This structural parameter change reduces the crossing angle needed for stability, which in turn reduces the mechanical load and power consumption of the thread guide system while maintaining yarn integrity.
3Stability of the object's composition
If the crossing angle is increased to reduce thread knock-offs, then edge stability is improved, but package density is significantly reduced
Solution Approach 1:
The bobbin is pre-shaped with rounded end faces or tapered geometry before winding begins. This preliminary structural configuration guides the thread layers to naturally form stable edges during the winding process, eliminating the need to increase the crossing angle for edge stability, and thus maintaining high package density while achieving stable edges.
Solution Approach 2:
The patent modifies the bobbin's geometric parameters (end face curvature radius, taper angle) to create a structure that inherently stabilizes thread layers at the edges. This structural parameter change allows edge stability to be achieved through the bobbin shape rather than through increased crossing angles, thereby maintaining high package density while ensuring stable edges.
Data Source
Figure 1~3
AI summary
Outer layers of the bobbin (21) winding are wound-on over a width which is reduced in comparison with that of layers underneath, in the main winding. The outer layers are added to a maximum thickness of 3-20 mm, but their winding angle is not increased. The winding width in the outer layers decreases continuously. End faces of the bobbin chamfer-down at the edges, towards the center of the bobbin. Alternatively, the winding width of the outer layers reduces abruptly, the decrease being stepped. A machine is designed to form the bobbin.