Lifting Thread Cog Formation Without Heat or Yarn Rotation
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Solution Overview
Problem
Conventional lifting thread manufacturing methods involve heat treatment, which alters the physical properties of the yarn and reduces tensile strength, and rotating the yarn to form cogs leads to durability issues, while the process is inefficient due to intermittent steps.
Innovation Solution
A lifting thread manufacturing apparatus that forms cogs without heat, rotates in multiple directions without yarn rotation, and performs continuous processes from yarn supply to packaging, including a supply unit, processing unit, assembling unit, and packaging unit, ensuring high-quality production under room temperature conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heat treatment is used to form cogs on the lifting thread, then the cogs can be formed effectively, but the physical properties of the yarn are altered and tensile strength is reduced
Solution Approach 1:
The invention changes the temperature parameter from high (heat treatment) to low (room temperature or lower) to form cogs without altering the physical properties of the yarn. This is achieved by using a cooling unit that maintains the yarn at room temperature or below during the cog formation process, thereby preserving tensile strength while still enabling effective cog formation through controlled deformation.
Solution Approach 2:
The invention replaces the thermal field (heat treatment) with a mechanical field (controlled deformation at low temperature). Instead of using heat to soften and form the cogs, the system uses mechanical compression and shaping forces applied to the yarn while it remains at room temperature, thus avoiding thermal degradation of the yarn's physical properties.
2Adaptability or versatility
If the yarn is rotated to form cogs in multiple directions, then multidirectional cogs can be created, but the tensile strength and durability of the lifting thread deteriorate
Solution Approach 1:
Instead of rotating the yarn to form multidirectional cogs (which causes durability issues), the invention inverts the approach by keeping the yarn stationary and rotating the processing unit or forming tools around the yarn. This allows multidirectional cogs to be formed without subjecting the yarn to repeated rotation stresses that would compromise its tensile strength and durability.
Solution Approach 2:
The invention segments the cog formation process into multiple sequential steps, where cogs are formed in different directions through separate compression and shaping operations rather than through continuous yarn rotation. This segmented approach allows each cog to be formed with controlled force and minimal stress on the yarn, preserving overall thread integrity.
3Ease of manufacture
If intermittent separate steps are used for yarn processing, cog formation, assembly, and packaging, then each process can be performed separately, but work efficiency is low
Solution Approach 1:
The invention merges multiple separate process steps (yarn supply, cooling, cog formation, assembly, and packaging) into a single integrated continuous production line. The processing unit combines the cooling unit, compression unit, and forming unit in sequence, allowing yarn to flow continuously through all stages without interruption or manual intervention, thereby dramatically improving work efficiency while maintaining process control.
Solution Approach 2:
The invention implements continuous action throughout the manufacturing process, where yarn is supplied continuously, cooled continuously, and cogs are formed continuously without interruption. The integrated system eliminates idle time between operations and maintains constant productive action from raw yarn input to finished product output, maximizing productivity.
Data Source
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AI summary
An apparatus for manufacturing a lifting thread is provided. In one embodiment, the apparatus comprises: a supply part for supplying a yarn; a processing part for manufacturing a lifting thread by forming multidirectional cogs on the surface of the yarn supplied from the supply part; an assembling part that prepares a lifting thread assembly by assembling a tube and a cover with the lifting thread prepared in the processing part; and a packaging part that sterilizes and packages the lifting thread assembly prepared in the assembling part, whereby the efficiency of the process of manufacturing the lifting thread can be improved by continuously performing the entire process from the processing of the yarn to the sterilization packaging of the lifting thread assembly, and the lifting thread having high quality and reliability can be manufactured by performing the entire process under room temperature conditions without applying heat to the yarn.