Variable Yarn Injection Device Using Pneumatic Suction
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Solution Overview
Problem
Existing devices for inserting yarn sections into substrates face challenges such as the need for large and heavy components, high energy consumption for operation, and limitations in adjustable insertion depths.
Innovation Solution
A yarn injection device with a feeding system that uses extendable yarn tubes and moveable cutting devices, along with a fluid flow assembly that creates a drag force to pull yarns through the device, allowing for adjustable yarn section lengths and insertion depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If pressurized air is fed into the tube via a venturi device to force the fiber through, then the fiber can be pushed through the tube, but the pressure and velocity of the air rapidly decrease inside the tube requiring a large expensive compressor
Solution Approach 1:
Instead of pushing the fiber through the tube using pressurized air from the feeding end, the invention inverts the approach by using suction at the injection end to pull the fiber through the tube. The injection needle creates a pressure difference that draws the fiber along the supply path, eliminating the need for high-power compressors while maintaining effective fiber transport.
Solution Approach 2:
The invention utilizes pneumatic principles by creating a pressure difference through the injection needle's movement. The needle's displacement generates suction that pulls the fiber through the tube, leveraging fluid dynamics to achieve fiber transport without requiring mechanical pushing systems or large compressors.
2Ease of operation
If the injection pin moves downwards at the intersection with the tube, then the pin can be positioned for injection, but pressurized air may escape through the open space causing fiber loss and jamming
Solution Approach 1:
The invention inverts the pressure approach by using suction instead of pressurization. The injection needle creates a negative pressure zone that pulls the fiber through, preventing air and fiber from escaping through open spaces. This suction mechanism maintains reliable fiber transport even when the injection pin is in its downward position.
Solution Approach 2:
The system prepares for potential fiber loss by using suction to continuously draw the fiber through the tube before injection. This preliminary action counteracts the tendency of pressurized air to escape with the fiber, ensuring the fiber remains in the tube and reaches the injection point reliably.
3Ease of operation
If a rotating drum with clamps is used to hold and rotate yarn strands, then the strands can be fed to cutting devices, but the large heavy drum requires strong frames and consumes large amounts of energy for acceleration and deceleration
Solution Approach 1:
The invention replaces the mechanical rotating drum system with a pneumatic suction system. The injection needle's movement creates a pressure difference that pulls the yarn through the tube, eliminating the need for heavy rotating components, strong frames, and the associated high energy consumption for acceleration and deceleration.
Solution Approach 2:
The invention substitutes the mechanical drum-rotation system with a pneumatic suction mechanism. Instead of using mechanical force to feed and position the yarn, the system uses pressure differential created by the injection needle to draw the yarn through the tube, significantly reducing mechanical complexity and energy requirements.
4Adaptability or versatility
If the cutting device is moved relative to the injection pins to adjust fiber length, then variable insertion depths are achieved, but the open space increases causing more air leakage and fiber escape
Solution Approach 1:
The invention inverts the pressure mechanism to use suction instead of pressurization. This allows the cutting device to be moved for adjusting fiber length without increasing air leakage, as the suction force continuously draws the fiber through the tube regardless of the open space created by moving components.
Solution Approach 2:
The suction mechanism creates a preliminary counteracting force that prevents air and fiber from escaping through open spaces created by moving the cutting device. This ensures reliable fiber transport and injection even when adaptability features create additional open areas in the system.
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 efficiently inserts yarn sections into substrates with adjustable depths, reduces energy consumption by only creating a pressure difference when needed, and minimizes material usage and environmental impact.
Implementation Method 1
a fluid flow assembly configured to create a pressure difference to generate a drag force that pulls the yarn through the yarn tubes and into the substrate
Implementation Method 2
a fluid flow assembly configured to create a pressure difference
Data Source
AI summary
Yarn injection device for injecting yarn sections into a substrate, wherein the yarn injection device comprises:—a yarn storage for holding a number of spools with yarn,—a feeding device configured to feed lengths of yarn to an injection unit, the feeding device comprising: ⋅a number of yarn tubes, each yarn tube defining a yarn channel configured to accommodate a respective yarn, ⋅a number of cutting devices located being configured to cut a number of yarn sections,—the injection unit comprising: ⋅an injection needle guide defining a number of first passages extending over a vertical distance and a number of second passages extending over a horizontal distance, ⋅a number of moveable injection needles configured to pass through the first holes of the injection needle guide, wherein yarn sections in the yarn tubes located below the moveable injection needles are injected into the substrate when the moveable injection needles move downward through the injection needle guide, ⋅at least one needle actuator configured to move the number of moveable injection needles,—a fluid flow assembly, wherein at least one fluid communication channel extends between the injection needle guide and the depressurized or pressurized compartment, wherein the fluid flow assembly is configured to create a flow of fluid through each fluid communication channel, each injection needle guide and each yarn tube in order to apply a drag force on the yarns and move the yarns through the second passages in the injection needle guide.