Yarn Heater Contact Surface Orientation for Fusion Prevention

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Solution Overview

Problem

Existing yarn processing methods face inefficiencies in heating synthetic fibers, leading to yarn breakage and fusion with the heater, particularly when using contact heating methods, where temperatures are limited to prevent fusion, and contactless methods struggle with high temperatures required for efficient heating.

Innovation Solution

A yarn processing method utilizing a heater with a contact surface oriented downward and an inclination angle between -60 to 60 degrees, heated to a temperature range of 230 to 350 degrees Celsius, allowing for higher heating efficiency while preventing yarn fusion during breakage by enabling the yarn to quickly leave the contact surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If contact heating method is used to heat synthetic fiber yarn, then heating efficiency is improved, but yarn melts and adheres to the heater when yarn breakage occurs

Engineering Contradiction:

Improveheating efficiencyVSAvoidyarn adhesion to heater

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The contact surface is oriented downward at a specific inclination angle (-60 to 60 degrees), changing the spatial dimension of the heating interface. This geometric modification allows gravity to act on broken yarn ends, causing them to detach from the heater surface rather than adhere, thus resolving the contradiction between efficient heating and adhesion prevention

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The inclination angle of the contact surface is controlled within a specific range (-60 to 60 degrees), optimizing the balance between heating efficiency and yarn detachment. This parameter adjustment ensures that broken yarn can slide off the heated surface under gravitational influence while maintaining effective thermal contact during normal operation

Inventive Principle:

Principle #35Parameter changes

2Productivity

If heating temperature is set high to increase heating efficiency, then heating efficiency is improved, but risk of yarn fusion increases

Engineering Contradiction:

Improveheating efficiencyVSAvoidrisk of yarn fusion

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention converts the potentially harmful effect of high temperature (which could cause yarn fusion) into a beneficial effect by combining it with the downward-oriented contact surface. The high temperature provides efficient heating, while the geometric design ensures that any melted yarn adhering to the heater will detach due to gravity, thus transforming the risk into a controlled process

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Object-affected harmful factors

If contactless heating method is used to avoid yarn adhesion, then yarn fusion is avoided, but heating efficiency decreases

Engineering Contradiction:

Improveyarn fusion avoidanceVSAvoidheating efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The invention introduces an intermediary geometric feature (the downward-oriented contact surface with specific inclination angle) that mediates between contact and contactless heating approaches. This intermediary structure allows the yarn to maintain thermal contact for efficient heating while providing a gravity-assisted escape path that prevents adhesion, thus bridging the gap between the two methods

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances heating efficiency and prevents yarn fusion during breakage, allowing for higher temperatures without adhering to the heater, while also reducing device size and power consumption by setting the heating temperature within a middle range.

Implementation Method 1

a heater including a heat source and a heating unit which is heated by the heat source

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the running yarn making contact with the contact surface... the yarn is heated to the processing temperature

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4112790A1Manufacturing method of processed yarn and yarn processor

Publication Date: 2023.01.04 TMT MACHINERY INC

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Figure 3(a)~3(d)

AI summary

An object of the present invention is to increase, when a yarn is heated and processed in a heater, a heating efficiency while avoiding risk of fusion in yarn breakage. A manufacturing method of processed yarns includes a step of heating a running yarn Y, which is made of synthetic fibers, by means of a first heater 13. The first heater 13 includes a heat source 51 and a heating unit 52. The heating unit 52 includes a contact surface 56 extending at least in a predetermined extending direction. The running yarn Y makes contact with the contact surface 56. In the manufacturing method, the contact surface 56 is oriented at least downward. Furthermore, the first heater 13 is provided so that an inclination angle of the contact surface 56 with respect to the horizontal direction is within a range of - 60 to 60 degrees in a cross section parallel to both a vertical direction and the extending direction. Furthermore, the temperature of the contact surface 56 is set at a predetermined temperature which is not less than 230 degrees centigrade and not more than 350 degrees centigrade. The yarn Y runs in this state while making contact with the contact surface 56.