Filamentary Material Processing With Integrated Crimping and Heat Setting
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Solution Overview
Problem
Existing textile processing devices require significant installation space, lack flexibility, and often result in non-uniform fabric appearance and limited bulking due to the separate operation of units for crimping and heat setting, which affects the durability and appearance of carpets.
Innovation Solution
A closed system integrating a delivery device, treatment device, transport device, and thermofixing device with subsystems for different temperature zones, allowing for continuous processing and heat setting within a controlled environment, reducing pressure points and enabling the production of both frieze and straight set yarns without mechanical component changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate units are used for crimping and heat setting, then the processing steps can be performed independently, but the installation space required increases and the system lacks flexibility
Solution Approach 1:
The patent combines the crimping device and heat-setting device into a single integrated unit. The crimping device is positioned within the heat-setting device, allowing both functions to be performed in one location. This merging eliminates the need for separate independent units, reducing installation space while maintaining the ability to perform both crimping and heat-setting operations.
Solution Approach 2:
The integrated device serves multiple functions within a single system. The heat-setting device not only performs thermal treatment but also houses the crimping device, enabling it to perform both heat-setting and mechanical deformation functions. This multi-functionality increases system versatility without requiring additional separate units.
2Ease of manufacture
If separate units are used for crimping and heat setting, then each unit can be optimized independently, but the system complexity increases
Solution Approach 1:
By integrating the crimping device within the heat-setting device, the patent reduces the number of separate components that need to be manufactured and assembled. The combined unit shares common structural elements and support systems, simplifying the overall manufacturing process while still allowing independent optimization of each functional component within the integrated design.
3Productivity
If separate units are used for crimping and heat setting, then the processes can be performed in sequence, but the production time increases
Solution Approach 1:
The integrated device enables continuous processing where crimping and heat-setting occur in sequence within the same operational cycle. The yarn passes through the crimping device first, then immediately through the heat-setting zone, eliminating the need to stop and transfer between separate units. This continuous action reduces total processing time and increases productivity.
Solution Approach 2:
The crimping operation is performed as a preliminary step within the heat-setting device before the thermal treatment begins. By pre-deforming the yarn structure while it is still in position, the subsequent heat-setting process can immediately follow without interruption, optimizing the sequence of operations and reducing overall processing time.
4Device complexity
If separate units are used for crimping and heat setting, then the equipment can be simpler individually, but the overall system requires more components
Solution Approach 1:
The patent merges two separate devices into one integrated unit, reducing the total number of components in the system. Instead of having independent crimping and heat-setting machines, the crimping mechanism is incorporated within the heat-setting device structure, eliminating redundant components and simplifying the overall system architecture.
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 solution enhances flexibility, reduces energy consumption, and improves product quality by allowing for efficient heat setting and bulking within a controlled environment, ensuring uniformity and increased durability of the yarns.
Implementation Method 1
Many of these finishing processes require a subsequent thermal setting, which is usually carried out in a steam atmosphere or under dry heat
Implementation Method 2
thermal setting, which is usually carried out in a steam atmosphere
Implementation Method 3
thermal setting, which is usually carried out in a steam atmosphere or under dry heat
Implementation Method 4
The successive heating and cooling causes the yarn to relax and, depending on the type of material, it can shrink and bulk up
Data Source
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AI summary
The invention relates to a method for the continuous processing of a filamentary material with several method steps and a device for carrying out the method. According to the invention, a delivery device (10), a treatment (35) and depositing device (36), a transport device (14), a heat setting device (32) and a length compensation device (37) are arranged in a common closed system (5) and the closed system (5) differs in its interior from the environment by at least one first physical property and within the system (5) there are subsystems (31, 32, 33, 35, 36, 37) shielded from one another for the various process steps, to the supply facilities (25, 26, 27) are connected, which at least partially produce different temperatures in the subsystems (31, 32, 33, 35, 36, 37) as a second physical property.