Spinning Roller Dual-Layer Elastic Design for Wear and Fiber Holding
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Solution Overview
Problem
Conventional spinning rollers face challenges in balancing fiber bundle holding ability with surface wear resistance, as high hardness rubber layers can degrade the ability to hold fibers while low hardness layers lead to increased wear.
Innovation Solution
A spinning roller design featuring a cylindrical pipe with a dual-layer elastic layer, where the first rubber layer has a durometer hardness of 30° to 38° and the second layer has a hardness of 60° or more, with a thickness ratio of 1/1 to 1/10, allowing for a wider nip width and improved fiber bundle holding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the hardness of the rubber that forms the roller surface is made higher to suppress wear, then wear resistance is improved, but the ability of the roller to hold a fibre bundle degrades and yarn becomes uneven
Solution Approach 1:
The elastic layer is divided into two distinct rubber layers: a first rubber layer with lower hardness (30° to 38°) that provides fiber bundle holding ability, and a second rubber layer with higher hardness (60° or more) that provides wear resistance. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
Different regions of the roller surface are given different hardness properties. The outer second rubber layer has high hardness for wear resistance where it contacts the fiber bundle, while the inner first rubber layer has low hardness for providing the necessary compliance to hold the fiber bundle. This local differentiation of material properties resolves the contradiction between wear resistance and fiber holding ability.
2Reliability
If a double-layer structure with a softer first rubber layer and harder second rubber layer is used to balance fiber holding ability and wear resistance, then both properties are improved, but significant differences in nip width occur among rollers with the same outer layer material and apparent hardness
Solution Approach 1:
The invention specifies precise parameter ranges for the first rubber layer hardness (30° to 38°) and the thickness ratio T2/T1 (1/1 to 1/10) to control nip width. By standardizing these parameters, the invention ensures consistent nip width across different rollers while maintaining the dual-layer structure that provides both fiber holding ability and wear resistance.
Solution Approach 2:
The invention uses a thickness ratio T2/T1 of 1/1 to 1/10, where the second rubber layer thickness T2 is controlled to be relatively thin compared to the first layer thickness T1. This partial action approach ensures that the softer first layer dominates the nip width formation while the harder second layer provides sufficient wear protection, achieving both fiber holding and wear resistance with consistent nip width.
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 solution enables a spinning roller with enhanced fiber bundle holding capability and reduced wear, producing consistent yarn quality while minimizing the risk of inconsistency and wear-related hardness decline.
Implementation Method 1
a cylindrical elastic layer fixed to an external surface of the pipe, the elastic layer including: a first rubber layer on an inner side; and a second rubber layer on an outer side, fixed to the first rubber layer
Implementation Method 2
the ability of the roller to hold a fibre bundle would degrade and the yarn may become uneven
Data Source
Figure 1~2
Figure 3
AI summary
Provided is a spinning roller including: a cylindrical pipe configured to have an arbor inserted therein; and an elastic layer fixed to the external surface of the pipe. The elastic layer includes: a first rubber layer on the inner side; and a second rubber layer on the outer side, fixed to the first rubber layer. The hardness of the first rubber layer is 48° or less and the hardness of the second rubber layer is 60° or more. The thickness of the elastic layer is 2 to 20 mm. The ratio of a thickness T2 of the second rubber layer to a thickness T1 of the first rubber layer: T2/T1 is 1/1 to 1/10 and preferably 1/3 to 1/6.