Yarn Tuft Holder with Segmented Comb for Carpet Weaving
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Solution Overview
Problem
Existing yarn tuft holders in carpet manufacturing machines lack accurate control over tuft position and transfer, leading to incorrect or failed transfers, resulting in yarn wastage and loom downtime.
Innovation Solution
A yarn tuft holder with a resiliently deformable comb portion for secure tuft retention and a rigid comb portion for guiding grippers, ensuring accurate and reliable transfer of tufts to weaving positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid comb portion is used to guide grippers, then manufacturing precision is improved, but the ability to securely hold tufts is worsened
Solution Approach 1:
The comb portion is divided into two distinct segments: a rigid comb portion for guiding grippers and a resiliently deformable comb portion for holding tufts. This segmentation allows each segment to be optimized for its specific function - the rigid portion provides precise positioning while the resilient portion provides secure retention through elastic deformation.
Solution Approach 2:
Different regions of the comb structure are given different mechanical properties. The rigid comb portion maintains its stiffness for accurate gripper guidance, while the resilient comb portion is specifically designed to be deformable for secure tuft holding. This local differentiation of material properties resolves the contradiction between rigidity and flexibility requirements.
2Ease of operation
If longer tufts are used to facilitate gripping, then ease of operation is improved, but yarn wastage increases
Solution Approach 1:
The invention changes the mechanical parameter of the comb portion from rigid to resiliently deformable, which alters how the tufts are held and presented to grippers. This parameter change enables secure retention of tufts with appropriate length, eliminating the need to use excessively long tufts to ensure reliable gripping, thus reducing yarn wastage while maintaining ease of operation.
3Manufacturing precision
If accurate tuft positioning is achieved, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
By segmenting the comb into rigid and resilient portions, the device achieves accurate tuft positioning through the rigid portion's structural stability while the resilient portion automatically adapts to secure tufts. This segmentation provides precise control without requiring additional complex positioning mechanisms, sensors, or actuation systems.
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 solution provides improved control and reliability in transferring yarn tufts, reducing wastage and downtime by securely holding and guiding tufts during the carpet weaving process.
Implementation Method 1
a resiliently deformable comb portion for receiving and holding yarn tufts
Data Source
AI summary
A yarn tuft holder (11) for holding yarn tufts received from one or more yarn tuft inserting devices (2) prior to removal by grippers (13) of a carpet manufacturing machine, comprising a resiliently deformable comb portion (17) for receiving and holding yarn tufts and a rigid comb portion (16) disposed adjacent the resiliently deformable comb portion and for guiding grippers configured to remove yarn tufts held by the resiliently deformable comb portion. Also, a loom for making carpet, comprising one or more of the yarn tuft holders, and a method for making carpet using the loom.