Flangeless Yarn Package Stepped Structure
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Solution Overview
Problem
The existing yarn winding technologies face challenges with high unwinding tension and latching issues, particularly with natural fibers like cotton, leading to tension breakage and contamination, which affects the unwindability of packages manufactured by spinning machines.
Innovation Solution
A package design with a flangeless winding member and alternating yarn layers of different diameters, where the first yarn layer and second yarn layer are wound alternately to reduce unwinding tension and avoid latching zones, and a yarn winding device with a control section to manage the winding process, using a lever member to adjust traverse widths and guide the yarn through different grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flanges are added to the winding member to prevent yarn from touching the yarn layer during unwinding, then yarn breakage is reduced, but the natural fiber becomes fluffy and unwindability deteriorates
Solution Approach 1:
The invention removes the flanges from the winding member, extracting the problematic component that caused fiber fluffing. By eliminating the flanges entirely and using a flangeless winding member, the yarn can unwind smoothly without rubbing against flange surfaces that generate heat and cause natural fiber entanglement.
Solution Approach 2:
The invention changes the dimensional approach by creating a stepped structure with multiple levels (first portion, second portion, third portion at different diameters) instead of using flanges at the ends. This dimensional variation in the yarn layer configuration prevents yarn contact with underlying layers during unwinding without requiring end flanges.
2Ease of manufacture
If the yarn is wound with constant diameter layers, then the winding process is simple, but the yarn touches the yarn layer during unwinding causing high tension and latching
Solution Approach 1:
The yarn layer is segmented into distinct portions at different diameters (first portion at first diameter, second portion at second diameter, third portion at third diameter). This segmentation creates a stepped structure where each portion is wound at a different diameter level, preventing yarn contact during unwinding while maintaining manufacturing feasibility through automated winding with diameter variation.
Solution Approach 2:
Different portions of the yarn layer have different local qualities in terms of diameter. The first portion, second portion, and third portion are each wound at specific different diameters, creating local variations that prevent yarn-lay contact during unwinding. This local quality differentiation solves the unwindability problem while maintaining overall structural integrity.
3Stability of the object's composition
If flanges are used to contain the yarn layers, then layer stability is improved, but friction and heat generation cause latching and tension breakage
Solution Approach 1:
The invention extracts and removes the flanges from the winding member, eliminating the source of friction and heat generation. By using a flangeless design, the harmful thermal and mechanical effects on natural fiber yarn are eliminated, allowing smooth unwinding without latching or tension breakage.
Solution Approach 2:
Instead of containing yarn layers through end flanges (one-dimensional containment), the invention uses a multi-level stepped structure with portions at different diameters (three-dimensional configuration). This dimensional approach provides layer stability through spatial separation rather than mechanical containment, eliminating friction and heat issues.
Data Source
Figure 1
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Figure 3~4
AI summary
To improve unwindability and suppress the latching in the package. The package 7 includes a winding tube 6 having no initial level difference and having both ends flangeless, and a yarn 4 wound around it. The yarn 4 includes a first step 7A and a second step 7B arranged with each other in a longitudinal direction of the winding tube 6. The second step 7B has a diameter larger than that of the first step 7A. The yarn 4 includes a first yarn layer 51 and a second yarn layer 53 alternately layered with each other. The first yarn layer 51 is wound with a width (A) from a reference end (P) corresponding to the first step 7A and the second step 7B. The second step 7B is wound with a width (B) narrower than the width (A) only corresponding to the second step 7B.