Fabric Fiber Defibration and Garnetting for Twisted Thread Recycling
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Solution Overview
Problem
Existing methods for recycling fiber products, such as those described in JP-T-2017-531103, fail to effectively separate fibers that are tightly twisted, leading to reduced yield and unusable fibers.
Innovation Solution
A fiber processing method involving defibration and garnetting processes to separate and untangle fibers, starting with coarse fragments of fabric containing twisted threads, using a defibration device to produce a first defibrated material and a garnetting device to further untangle fibers, resulting in a second defibrated material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If only garnetting processing is performed on cut fabric pieces, then the process is simple, but fibers that are tightly twisted cannot be finely separated
Solution Approach 1:
The fiber processing method is divided into two distinct stages: defibration processing (first stage) and garnetting processing (second stage). The defibration stage specifically targets and separates tightly twisted fibers using a defibrator, while the garnetting stage further refines the separation. This segmentation allows each stage to be optimized for its specific function, enabling effective separation of tightly twisted fibers without requiring excessive complexity in a single processing step.
Solution Approach 2:
Defibration processing is performed as a preliminary action before garnetting processing. By pre-separating the tightly twisted fibers through defibration, the subsequent garnetting process can focus on refining the separation of already-loosened fibers. This preliminary action makes the overall process more effective for tightly twisted materials, as the defibration stage prepares the material in a state that is more amenable to fine separation in the garnetting stage.
2Productivity
If conventional cutting and garnetting methods are used, then the process is straightforward, but fiber yield is reduced due to inability to separate tightly twisted fibers
Solution Approach 1:
The processing method is segmented into defibration and garnetting stages, with the defibration stage specifically designed to handle tightly twisted fibers. This segmentation ensures that no fibers are lost due to inadequate separation, as the defibration stage captures and separates fibers that would otherwise remain bound in tight twists. The result is maximum fiber yield, as all separable fibers are recovered regardless of their initial twist tightness.
Solution Approach 2:
The defibration process acts as an intermediary step between cutting and garnetting. It serves as a mediator that transforms tightly twisted fibers into a state suitable for fine separation. By introducing this intermediary defibration stage, the system achieves complete fiber separation and maximizes yield, as the defibrator specifically targets and loosens tightly bound fibers before they enter the garnetting process.
3Manufacturing precision
If multiple processing steps are added to separate tightly twisted fibers, then fiber separation quality improves, but processing time increases
Solution Approach 1:
The processing method is segmented into two specialized stages: defibration (for separating tightly twisted fibers) and garnetting (for fine separation). This segmentation allows each stage to be highly efficient at its specific task, reducing the need for repeated or prolonged processing. The defibration stage quickly loosens tightly bound fibers, and the garnetting stage rapidly completes the fine separation, minimizing total processing time while achieving high separation quality.
Solution Approach 2:
The processing method changes key parameters between stages: defibration uses high-speed rotation and impact forces to separate tightly twisted fibers, while garnetting uses differential rotation speeds and comb-like structures for fine separation. By optimizing parameters for each specific separation task, the process achieves high-quality fiber separation in each stage, reducing the need for extended processing times or additional redundant steps.
Data Source
AI summary
A fiber processing method includes performing defibration processing on a coarse fragment of a fabric containing a thread in which a plurality of fibers are twisted to produce a first defibrated material; and performing garnetting processing on the first defibrated material to produce a second defibrated material. The fiber processing method may further include, before performing the defibration processing, coarsely fragmenting the fabric to produce the coarse fragment.