Segmented Patterning Shell for Fast Textile Drum Changeover

Solution Overview

Problem

The existing thermal treatment apparatuses for textile webs require time-consuming and labor-intensive replacement of patterning shells, which disrupts production due to the need for complete removal and reinstallation of large, structured shells.

Innovation Solution

The apparatus features a patterning shell composed of detachable segments connected via elements integrated into the ridges, allowing for easy assembly and disassembly without disrupting the pattern, using pins, mandrels, or circulating belts to ensure a seamless and secure fit on the drum.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a complete patterning shell is used on the drum, then a uniform pattern is produced on the textile web, but the replacement of the patterning shell becomes very time-consuming and labor-intensive

Engineering Contradiction:

Improvepattern uniformityVSAvoidreplacement time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patterning shell is divided into multiple detachable segments that can be assembled and disassembled independently. Each segment contains pattern elements and can be connected to adjacent segments through connecting elements, allowing partial replacement without removing the entire shell, thus reducing replacement time while maintaining pattern uniformity across the complete working width

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If a complete patterning shell is used on the drum, then a uniform pattern is produced on the textile web, but the replacement requires removal of parts of the housing and extensive retooling measures

Engineering Contradiction:

Improvepattern uniformityVSAvoidretooling complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patterning shell is divided into multiple detachable segments that can be assembled and disassembled independently. Each segment contains pattern elements and can be connected to adjacent segments through connecting elements, allowing partial replacement without removing the entire shell, thus reducing replacement time while maintaining pattern uniformity across the complete working width

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patterning shell segments are designed to fit onto the drum in a nested manner, with each segment containing pattern elements that align with the drum's rotation axis. The segments can be inserted and secured without removing the drum or housing, simplifying the replacement process

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If connecting elements are arranged outside the working width of the patterning shell, then assembly is simplified, but the segments do not rest flat on the drum causing irregularities in the pattern

Engineering Contradiction:

Improveassembly easeVSAvoidpattern uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Connecting elements are strategically positioned at specific locations on the segments - some are integrated into ridges at the periphery while others are arranged on the inner circumference. This localized placement ensures that connection points do not interfere with the pattern-forming surfaces, allowing segments to rest flat on the drum and produce uniform patterns while maintaining assembly simplicity

Inventive Principle:

Principle #3Local quality

4Strength

If connecting elements are arranged on the pattern-producing surface, then segments are securely connected, but irregularities appear in the pattern that prevent processing over the complete working width

Engineering Contradiction:

Improveconnection strengthVSAvoidpattern uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Connecting elements are strategically positioned at specific locations on the segments - some are integrated into ridges at the periphery while others are arranged on the inner circumference. This localized placement ensures that connection points do not interfere with the pattern-forming surfaces, allowing segments to rest flat on the drum and produce uniform patterns while maintaining assembly simplicity

Inventive Principle:

Principle #3Local quality

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 design significantly reduces downtime by enabling quick replacement of patterning shells, maintaining a uniform pattern and allowing for efficient processing of textile webs across the complete working width, enhancing production efficiency and reducing personnel requirements.

Implementation Method 1

a heated gas, for example air, flows through the material web, thereby resulting in a drying or hardening

Methodology Applied

Scientific EffectHot air flow: Convection

Implementation Method 2

a thermal bonding of the material web as a result of the hot air and/or gas flowing in which can at least partially melt the fibers, which can consist of polyamide, into each other

Methodology Applied

Scientific EffectThermal bonding: Melting

Data Source

PatentUS10132020B2Apparatus for the thermal treatment of a textile web

Publication Date: 2018.11.20 TRÜTZSCHLER GRP SE

AI summary

An apparatus for a thermal treatment of a textile web includes at least one drum with a perforated casing surface around which a material web can be at least partially wrapped, at least one connecting element, and a patterning shell with a plurality of openings separated by ridges fitted onto the casing of the drum. The patterning shell includes at least two segments detachably connected with aid of the at least one connecting element. The at least one connecting element is arranged on or integrated into a ridge.