Pneumatic Textile Recycling Plant for Wadding Production
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Solution Overview
Problem
Current methods for recycling padded textile products are inefficient, requiring manual separation and processing, resulting in unsuitable wadding for clothing and furniture, and are resource-intensive with high energy consumption and pollution.
Innovation Solution
A mechanized process and plant that recycles padded textile products in a single operation, using rotating plates and cylinders to defiber and compress materials, producing insulating wadding without manual intervention, with low energy consumption and no water or pollution, capable of processing over 200 garments per hour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual separation and traditional Garnett machines are used to process recycled textile fibers, then the fibers can be processed, but the resulting wadding is too compact and not suitable for clothing and furniture padding
Solution Approach 1:
The patent replaces traditional mechanical Garnett machines with a pneumatic system that uses air currents to separate and transport textile fibers. This substitution allows fibers to be fluffed and aerated rather than compacted, producing wadding with the required loft and insulation properties for clothing and furniture applications
Solution Approach 2:
The invention changes the physical parameters of fiber processing by using controlled air pressure and flow rates instead of mechanical cutting and compression. The pneumatic system adjusts air current velocity and direction to achieve proper fiber distribution and wadding density, transforming the physical state from compact to aerated
2Productivity
If manual separation of garment components is performed, then material selection is possible, but the process requires expensive and lengthy manual operations with considerable time and electricity consumption
Solution Approach 1:
The pneumatic system performs automatic separation and sorting of textile fibers based on their natural aerodynamic properties. Heavier components sink while lighter fibers are carried away by air currents, eliminating the need for manual selection and reducing both processing time and energy consumption while maintaining material quality
Solution Approach 2:
The invention extracts and removes heavy non-fiber components (zippers, buttons, metal parts) from the textile waste stream using the pneumatic separation process. These denser materials are naturally separated by gravity and air resistance, allowing pure fiber material to be processed without manual intervention
3Ease of manufacture
If traditional mechanical processing methods are used to treat recycled fibers, then fibers can be separated, but the process involves high electricity consumption and considerable operational effort
Solution Approach 1:
The patent replaces electricity-intensive mechanical processors with a pneumatic system driven by controlled air flow. The separation and processing functions previously requiring high-power motors are achieved through aerodynamic forces, significantly reducing electricity consumption while simplifying the manufacturing process
Solution Approach 2:
The invention uses pneumatic principles to create controlled air currents that perform fiber separation, transport, and fluffing operations. The system employs air pressure differentials and flow velocity control to achieve complex processing tasks that would otherwise require multiple mechanical stages, reducing both energy consumption and process complexity
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
The process efficiently produces high-quality wadding for clothing and furnishing sectors, reducing resource usage and pollution, with significant oil savings and minimal environmental impact, while maintaining the origin of the recycled materials through traceable fragments.
Implementation Method 1
a first pair of rotating plates (7, 8) are provided, the facing surfaces of which have needles (11, 12), with different sizes and density, in a staggered arrangement between the needles (11) of the plate (9) and the needles (12) of the plate (10), so that the product (1) coming from the compression station (4) is defibred and torn into fibrous material
Implementation Method 2
said station (13) is provided with two pairs of cylinders (14, 15) which transform the fibrous material prepared in the previous station (6) into a layer of parallelized fibers
Implementation Method 3
The product (1) thus processed in the compression station (4) is then transferred, by means of a conveyor belt (3), to a decontamination chamber (2), which allows a bactericidal action to be performed thereon, for example through contact with UV radiation, with an ozone current and the like
Data Source
AI summary
A process and plant for making wadding or fiber flocks starting from a padded textile product, in which processing is carried out together and simultaneously of all the textile materials forming the same starting padded product. The process includes defibering and tearing, together and simultaneously, of fabric and wadding fibers forming the padded textile product, with formation of a single wadding layer, subsequently transformed into wadding flocks.