Spreader roll and device for smoothing a textile material using a spreader roll
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Solution Overview
Problem
Existing spreading rollers fail to effectively smooth fabric layers with both longitudinal and transverse tensions when a relative speed occurs between the roller's circumferential speed and the fabric's travel speed, often intensifying creases instead of removing them.
Innovation Solution
A spreading roller designed as a round brush with bristles grouped into spaced-apart bundles, where bristle bundles on both sides of a transverse central plane run obliquely, allowing for both transverse and longitudinal tensions by pivoting within recesses in the base body, enhancing the trailing and leading-up effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a textile material is conveyed through processing machines on a knit fabric basis, then the fabric structure can be processed, but fabric defects such as slubs and thick/thin places are not eliminated and may be accentuated
Solution Approach 1:
The spreading mechanism divides the textile material into individual fibers or filaments using a spreading element with protrusions that separate and distribute the material uniformly across the spreader roll surface, preventing defects while maintaining continuous processing
Solution Approach 2:
A doffer roll acts as an intermediary between the spreader roll and the textile material, receiving the spread material and transferring it to the next processing stage, enabling defect elimination without disrupting production flow
2Manufacturing precision
If a spreader roll with a spreading element is used to spread textile material, then uniform spreading is achieved, but the spreading element may build up material and become clogged
Solution Approach 1:
The doffer roll periodically contacts the spreader roll surface to remove accumulated material, creating a cyclic cleaning action that prevents clogging while maintaining continuous spreading operation
Solution Approach 2:
The doffer roll automatically removes material buildup from the spreader roll through their rotational contact, providing self-cleaning functionality without requiring external intervention or stopping the process
3Ease of operation
If the spreader roll rotates in the same direction as the textile material conveyance, then material buildup on the spreader roll is reduced, but the spreading effectiveness may be compromised
Solution Approach 1:
The spreader roll has different rotational speeds or directions in different zones, with the surface contact area rotating to prevent buildup while maintaining the spreading action effectiveness at the point of material application
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 design effectively stretches fabric in both directions perpendicular to the roller's travel direction, removing creases and folds efficiently even with relative speed, using adjustable bristle stiffness and orientation to achieve uniform smoothing.
Implementation Method 1
the spreader roll (10) rotates in a direction in which the textile material is conveyed... the spreader roll rotates in the same direction as the textile material is conveyed... material buildup on the spreader roll is reduced
Implementation Method 2
a pressing device (20) is provided with a pressing element (21) that presses the textile material against the spreader roll (10)
Data Source
Figure 1~4
Figure 5~6
Figure 7~11
AI summary
The invention relates to a spreader roll (1) for smoothing a fabric layer, having protruding bristles (5) of bristles bundles (4) which are fixed to the main part (3) by means of a securing section (11). Bristle bundles (4) arranged on both sides of a transversal central plane (9) of the main part (3) are arranged so that the free end sections of the bristle bundles are inclined in the direction of the ends (7 and 8) of the main part (3) so that a transversal tension can be achieved on the fabric layer. In order to smooth a fabric layer even in the event of a relative speed between the circumferential speed of the spreader roll and the travel speed of the fabric layer using tension in the fabric layer both in the longitudinal direction as well as in the transversal direction, a sub-section of each bristle bundle (4) which runs diagonally and adjoins the securing section (11) is received by a recess (10) formed in the main part (3), said recess running substantially both in the radial direction as well as in the axial direction of the main part (3), wherein the bristle bundle (4) is guided on first lateral walls (12, 13) which extend in the axial direction of the main part (3), and the respective bristle bundle (4) running at a diagonal angle to the surface of the fabric layer (19) is deviated in the direction of a second lateral wall (15) of the recess (10) by an application of force at the free bristle ends (14), said second lateral wall delimiting the recess (10) in the direction of the respective end (7, 8).