Textile Yarn Shrinking via Extrusion Parameter Control
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Solution Overview
Problem
Existing methods for producing textile products with varying pile heights require cumbersome and expensive processes, such as using shrink acrylic or after-treatments like twisting and drawing, which are time-consuming and not feasible for producers with in-house extrusion lines.
Innovation Solution
Producing synthetic textile yarns with different shrinking capabilities using the same extrusion line by varying process parameters like temperature, air flow, and draw speed, without the need for after-treatments like twisting or drawing, allowing for the creation of pile height differences during a heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shrink acrylic yarns are used to produce different pile heights, then the desired pile height variation is achieved, but the production cost increases significantly
Solution Approach 1:
The patent changes the process parameters of the extrusion line to produce yarns with different shrinking capabilities. By adjusting temperature, air flow, and draw speed parameters during extrusion, the patent creates yarns that will shrink to different extents during heat treatment, thereby achieving different pile heights without using expensive shrink acrylic materials.
Solution Approach 2:
The patent replaces expensive shrink acrylic yarns with ordinary synthetic yarns (polyester, polyamide, or polypropylene) that are processed through modified extrusion parameters. This substitution uses cheaper, readily available materials that can be produced in-house using existing extrusion equipment, eliminating the need to purchase costly specialized yarns.
2Manufacturing precision
If after-treatments like twisting and drawing are applied to yarns, then different shrinking capabilities are achieved, but the production time increases
Solution Approach 1:
The patent performs the necessary actions to create different shrinking capabilities during the extrusion process itself, rather than as after-treatments. By adjusting extrusion parameters (temperature, air flow, draw speed) before the yarn is completed, the patent embeds the differential shrinking properties directly into the yarn structure, eliminating the need for subsequent twisting or drawing operations.
3Adaptability or versatility
If mechanical modifications to the extrusion line are made, then different yarn properties are achieved, but the device complexity increases
Solution Approach 1:
The patent achieves yarn property variation by changing operational parameters of existing extrusion line components rather than adding new machinery or making mechanical modifications. The patent adjusts temperature settings, air flow rates, and draw speeds using the existing equipment's control systems, thereby maintaining device simplicity while achieving versatility in yarn production.
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
Enables the production of textile products with varied pile heights using inexpensive raw materials and existing machinery, allowing for flexible design and pattern creation without mechanical modifications to the extrusion line, and achieving additional pile height differences through heat treatment.
Implementation Method 1
the yarns are subsequently subjected to a heat treatment which causes the first and second textile yarns to shrink differently
Implementation Method 2
the yarn may be drawn. This is carried out for the first time, for example, in the extrusion line during winding up of the yarn
Implementation Method 3
the temperatures of the one or several pairs of draw rolls just before the texturing unit; the speed of the one or several pairs of draw rolls just before the texturing unit
Data Source
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AI summary
The present invention relates to a method for producing a textile product (I), (II), comprising at least two synthetic pile threads (PI), (P2) having a different pile height, so that a predetermined design is formed, in which the synthetic pile yarns (PI), (P2) are manufactured by extrusion from the same raw material, according to production processes which only differ from each other by a different setting of one or several process parameters of their respective extrusion processes, so that they have a different shrinking capability, and in which the textile product (I), (II) is subjected to a heat treatment which causes the pile yarns (PI), (P2) to shrink differently. The invention also relates to such a method for producing synthetic textile yarns (PI), (P2) having a different shrinking capability.