Thermoplastic Thread Fusion Device for Warp Knitting
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Solution Overview
Problem
Existing thread connecting devices for thermoplastic textile threads often result in large-diameter knots that can easily catch on textile tools, leading to breakage or damage, and existing methods lack stability and precision in connecting multiple threads simultaneously.
Innovation Solution
A thread connecting device with two pressure elements and an energy input device, where the pressure elements are driven transversely to pinch and fuse thermoplastic textile threads, using ultrasonic or thermal energy to create a stable, small-diameter connection point that minimizes catching and allows for simultaneous connection of multiple threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a knotting device is used to connect two threads, then the threads can be connected together, but the resulting knot has a relatively large diameter that can easily get caught on textile tools
Solution Approach 1:
The patent replaces the mechanical knotting system with a thermoplastic fusion system. Instead of creating a mechanical interlocking knot, the invention uses heat and pressure to melt and fuse the thread ends together, forming a smooth connection point that does not protrude and cannot catch on tools. This substitution of mechanical joining with thermal joining resolves the contradiction between connection reliability and knot size.
Solution Approach 2:
The invention changes the physical state of the thread material from solid to molten and back to solid through controlled heating and cooling. By heating the thread ends to the melting point of the thermoplastic material and then fusing them under pressure, the connection point forms with a diameter only slightly larger than the original thread, eliminating the large-diameter knot problem while maintaining connection strength.
2Reliability
If elastic yarns are connected by thermocompression using a special device, then the connection is stable, but the device structure becomes complex
Solution Approach 1:
The patent integrates multiple functions into a single knitting needle component. The needle serves both as the knitting tool and as the heating element for thermocompression. The needle can be heated to melt thermoplastic threads during the knitting process itself, eliminating the need for separate specialized connection devices. This multi-functionality reduces device complexity while maintaining reliable connections.
Solution Approach 2:
The invention merges the knitting function and the thread connection function into a single integrated process. The heating element is incorporated directly into the knitting needle, allowing the needle to both knit the fabric and simultaneously fuse thermoplastic threads at the desired locations. This consolidation of functions simplifies the overall device structure compared to using separate specialized connection devices.
3Reliability
If a heating element is guided along the yarns to join them by heat, then the connection is achieved, but the process time increases
Solution Approach 1:
The patent enables continuous thread connection during the knitting process itself. The heating element is integrated into the knitting needle, allowing threads to be fused continuously as they are being knitted, rather than requiring separate intermittent connection steps. This continuous action eliminates idle time and integrates the connection process into the main production flow, significantly reducing total process time.
Solution Approach 2:
The invention incorporates the heating and fusion function into the knitting needle before the knitting process begins. The needle is pre-heated or equipped with heating capability, so that when threads are fed through the needle during knitting, they are immediately fused without requiring additional heating time. This preliminary preparation of the heating element enables simultaneous knitting and connection, reducing overall process time.
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 device achieves a stable and precise connection with a diameter only slightly larger than the threads, reducing the risk of catching and enabling efficient processing of multiple threads without the formation of large knots or shoulders, ensuring a homogeneous and stable connection.
Implementation Method 1
The energy input device is preferably an ultrasonic generator. The ultrasonic generator generates ultrasonic waves, which set the textile threads into high-frequency vibrations. This creates internal friction in the textile threads, which in turn heats up the textile threads.
Implementation Method 2
This creates internal friction in the textile threads, which in turn heats up the textile threads. The textile threads are heated up so much that they melt.
Implementation Method 3
The thermal energy generated by the heating element can be conducted to the thermoplastic textile threads by convection, thermal conduction and/or thermal radiation.
Implementation Method 4
The thermal energy generated by the heating element can be conducted to the thermoplastic textile threads by convection, thermal conduction and/or thermal radiation.
Implementation Method 5
Thermoplastic materials melt when heated. The energy input device supplies energy to the textile threads so that they can heat up and fuse together.
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a thread joining device (1) for joining a first thermoplastic textile thread (7) to a second thermoplastic textile thread (8). According to the invention, the thread joining device (1) comprises a pressure device (3) for exerting a mechanical pressure on a thread pair formed by the first thermoplastic textile thread (7) and the second thermoplastic textile thread (8), and an energy input device (4) for welding the thread pair while the thread pair is arranged in the pressure device (3). The invention further relates to a warp knitting machine with the thread joining device (1) according to the invention.