Textured Filament Cooling Drafting Rollers
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Solution Overview
Problem
Current methods for producing textured continuous filaments for textiles, especially for multi-colored yarns, face challenges in maintaining color clarity and crimp integrity due to filament sticking and mixing issues during the stretching and texturing process, leading to complex system requirements and reduced quality.
Innovation Solution
The process involves guiding filaments through a stretching device with pairs of inlet and drafting rollers, followed by a cooling drum and additional drafting rollers to actively cool the filaments to 0°C to 50°C, which enhances crimp fixation and elasticity, and uses separate knotting nozzles to prevent filament sticking, allowing for high-speed processing and clear color separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If yarn brakes are used to increase yarn tension after texturing, then yarn tension is increased, but friction and heat reduce the crimp which is detrimental to the final product
Solution Approach 1:
Instead of increasing yarn tension after texturing using yarn brakes (conventional approach), the invention inverts the approach by actively cooling the drafting rollers during the texturing process to maintain crimp while achieving the desired yarn tension through controlled cooling rather than friction-based tensioning
Solution Approach 2:
The invention replaces the mechanical friction-based tensioning system (yarn brakes) with a thermal control system (actively cooled drafting rollers) that achieves yarn tension control without the harmful friction and heat generation, thereby preserving crimp integrity
2Productivity
If multiple filaments are processed together through texturing die and cooling drum, then productivity increases, but filament sticking and color mixing occur reducing color clarity
Solution Approach 1:
The invention applies local quality control by actively cooling specific drafting rollers at different positions to maintain optimal temperature gradients that prevent filament sticking while allowing multiple filaments to be processed together, thereby preserving color clarity without sacrificing productivity
Solution Approach 2:
The invention changes the temperature parameter dynamically by actively cooling the drafting rollers during processing, which prevents filament sticking and color mixing while maintaining high productivity through continuous multi-filament processing
3Reliability
If drafting rollers are cooled to fix crimp after texturing, then crimp fixation and elasticity improve, but additional cooling system complexity is introduced
Solution Approach 1:
The drafting rollers serve multiple functions: they guide the yarn through the texturing process, apply tension, and actively cool the yarn to fix crimp. This multi-functionality reduces overall system complexity compared to having separate devices for each function
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 approach ensures the production of high-quality, multi-colored yarns with maintained crimp integrity and clear color clarity, simplifying the production process and reducing system complexity, even at high production speeds.
Implementation Method 1
a texturing device with a cooling drum is arranged
Implementation Method 2
The cooling is active, in that the drafting rollers are cooled internally by means of circulating media (air, water)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a device and a method for producing a textured filament or yarn, wherein at least one filament (F1...Fn) is guided into a drafting device (1), is guided there by a pair of inlet rollers (3.1, 3.2) to at least two pairs of drafting unit rollers (5.1, 5.2; 6.1, 6.2) and is drafted thereby, a texturing device (8) having a cooling drum (9) being arranged downstream of said drafting unit rollers (5.1, 5.2; 6.1, 6.2). The invention is characterized in that, downstream of the texturing device (8) having the cooling drum (9), at least one cooled drafting unit roller (10.1, 10.2, 15, 16, 11.1, 11.2) is arranged, the filament or yarn being cooled to a temperature of 0°C to 50°C thereby.