Yarn Heater with Localized Watt Density for Even Heating
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Solution Overview
Problem
Existing yarn heaters experience uneven heating due to temperature differences between the center and end portions of the heating unit, leading to inefficient power consumption and reduced yarn quality.
Innovation Solution
A heater design with a heat source having distinct parts along the yarn running direction, where the watt density of the resistive element varies to ensure even heating, including a first part with a higher watt density for end portions and a second part with a lower watt density at the center, controlled by a sensor and controller to maintain optimal temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the temperature of the center of the heating body is adjusted to the suitable temperature for heating the yarn, then the center temperature is adequate, but the end portions become excessively heated causing unnecessary power consumption
Solution Approach 1:
The heating body is designed with different heating capacities at different locations: the center portion has a first heating capacity while the end portions have a second heating capacity that is 0.5 to 0.8 times the first heating capacity. This local differentiation allows the end portions to be heated more efficiently without requiring excessive power, while the center provides sufficient heating for the yarn.
2Temperature
If the temperature of the end portions of the heating body is adjusted to the suitable temperature for heating the yarn, then the end portions are adequate, but the center becomes excessively heated causing unnecessary power consumption
Solution Approach 1:
The heating body incorporates a heating element with non-uniform heating capacity along its length. The end portions are designed with reduced heating capacity (0.5 to 0.8 times the center capacity) to prevent overheating, while still providing adequate heating for the yarn at the ends without requiring excessive overall power consumption.
3Temperature
If the temperature distribution is uniform across the heating body, then even heating is achieved, but the end portions cannot be adequately heated without excessive power consumption
Solution Approach 1:
Rather than achieving uniform temperature distribution through uniform heating capacity, the invention accepts non-uniform heating capacity design where the end portions have 0.5 to 0.8 times the heating capacity of the center. This allows adequate heating at the ends without excessive power consumption while maintaining suitable temperature distribution for yarn processing.
4Temperature
If the heating capacity at the end portions is increased to prevent temperature decrease, then even heating is achieved, but power consumption increases
Solution Approach 1:
The heating body is designed with optimized local heating capacities where the end portions have 0.5 to 0.8 times the heating capacity of the center portion. This differentiation prevents temperature decrease at the ends while avoiding excessive power consumption that would result from uniformly high heating capacity throughout.
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 design effectively suppresses temperature decreases at the end portions, ensuring even yarn heating and reducing power consumption while maintaining suitable temperatures for processing.
Implementation Method 1
a heat source of a resistance-heating type, which extends in a yarn running direction and which is configured to generate heat when an electric current is supplied to a resistive element
Data Source
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AI summary
An object of the present invention is to suppress the decrease in temperature of end portions of a heating unit in a yarn running direction and to further evenly heat a yarn running in the heating unit. A heat source 51 is provided to extend in the yarn running direction, and configured to generate heat when an electric current is supplied to a resistive element 51a. The heat source 51 is configured to heat the heating unit provided with a yarn running space in which the yarn runs. The heat source 51 includes: an entrance-side heating part 71 and an exit-side heating part 73 which are configured to heat both end portions of the heating unit in the yarn running direction, respectively; and a center heating part 72 at which the watt density of the resistive element 51a is lower than that at each of the entrance-side heating part 71 and the exit-side heating part 73. In this regard, the entrance-side heating part 71, the center heating part 72, and the exit-side heating part 73 are aligned in the yarn running direction.