TWI875722B - Metallic card for carding machine - Google Patents

Abstract

A metallic card (801) for use in carding machines has been disclosed. The card comprises a base (802) and a blade (803) formed on the base, the blade comprising teeth (804), characterized in that the teeth (804) comprises a tooth pitch (p), a first rising edge (8041) having a defined contour, transitions from a tooth root base (8042) to form a first tip (8043) of a first tooth, the first tip of the first tooth comprising a tooth height Dl from the tooth root base (8042), a working angle substantially between 0° to 50° formed by the first rising edge (8041) of the first tooth tip (8043), an angle substantially between 50° to 90° formed by a trailing edge (8044) of the first tooth; a second rising edge (8045) having a defined contour substantially transitions from a point (8046) at the tooth root base (8042) or a point (8046') at the trailing edge (8044) of the first tooth tip to form a second tooth, the second tooth comprising a height D3 from the point (8046) at the tooth root base (8042) or from the point (8046') at the trailing edge (8044) of the first tooth tip to a tip (8047) of the second tooth, a height D2 from the tip (8047) of the second tooth to the tooth root base (802), and a trailing edge (8048) from the tip (8047) of the second tooth being contoured to substantially transition into a rising edge(8041") of a subsequent first tooth tip (8043").

Description

Metal needles for carding machines

The present invention relates generally to metal card clothings, and more particularly to improved metal card clothings including separators such as projections in the tooth root to prevent fiber flow to the root, thereby preventing tooth damage and increasing tooth life.

Metallic card clothing is a carding element in a carding machine and is used in all textile plants to clean, individualize and parallelize the fibers. In the carding machine, the card clothing in the form of a continuous saw-tooth profile is wound around the carding drum. The card clothing generally consists of a base part and a blade part with teeth.

It is common to have a combed yarn with clear grooves between the teeth to facilitate fiber entry and flow through the grooves to the tip of the upcoming tooth, as shown in Figures 1 and 2. In this type of design, the fiber flow will go to the front edge of the tooth and be combed for fiber separation.

Increasing the life of the card clothing teeth by heat treating the teeth. Unfortunately, such a geometry of the teeth does not allow the teeth to get as high a hardening at the base as at the tip and therefore makes the root softer. In this way, it facilitates the installation of the card clothing but at the same time, it cannot meet the heavy wear of the fibers in high production needles and cannot withstand high tensile fibers, resulting in high wear and damage to the root and producing inefficient carding and poor life. For better visualization, conventional tooth cross-section images are shown in Figures 3 and 4. Figures 5 and 6 show damage in the root, where hardness may not have been achieved.

Any number of attempts to uniformly harden the tip to the root becomes cumbersome and produces high hardness in the root which is undesirable for wire installation in the application. Soft tooth bases cannot withstand abrasion from cotton and synthetic fibers. As a result, root damage causes turbulence and disturbs the fiber flow which reduces quality life and requires new clothing sets to be replaced prematurely.

Therefore, there is a need for a card clothing geometry and design that will prevent fiber flow to the soft root, thereby preventing tooth damage and increasing tooth life.

Reference may be made to patent application 1501/DELNP/2014, which discloses a metal needle thread comprising an elongated rib portion and teeth, wherein one or more ridges (which may be flattened ridges) are present on the back section of the teeth. The presence of ridges or flattened ridges and their size (especially without deep valleys) create an additional surface at the tip of the needle thread on which the fibers can rest by means of friction and by means of geometrical barriers, so that the fibers do not penetrate too deeply into the thread. Better carding is the result, since the fibers are more easily accessible from the top and the doffing machine.

Reference may be made to patent application IN201644010010, which discloses a tooth metal needle wiring having a first tip, a second tip, and an elevation angle at the back surface of the tooth.

Reference may also be made to patent application IN201744040340A, which discloses a needle wiring thread including a blade portion having a first tip and a second tip at the back surface of the tooth.

Reference may further be made to patent application WO2015154837A1, which discloses a needle wire design in which the teeth of a saw wire have a tooth profile that allows the tooth tip portion to be eroded as frequently as possible. For this purpose, a tooth tip is formed on the tooth tip portion, which is slightly reduced with each grinding operation and thus the tooth tip is simultaneously sharpened as it proceeds downward. For example, the saw wire may be re-ground several times until the tooth tip is completely ground on the tooth tip portion, and the tooth tip is formed by direct transformation from the tooth tip portion in the tooth face before the use of the saw wire ends.

Prior art literature has hitherto disclosed the formation of ridges, tooth tips, elevation angles and second teeth at the back surface of the tooth. These may result in minor prevention of fiber inflow into the root of the tooth but are not as efficient as the present invention.

The following content presents a simplified overview of the present invention to provide a basic understanding of some aspects of the present invention, neither identifying key elements nor defining the scope of the present invention. Its sole purpose is to present a certain concept of the present invention in a simplified form as a prelude to the more detailed description that is presented later.

One of the objects of the present invention is to prevent fibers from flowing into the tooth roots of metal card clothing in order to protect the teeth and substantially increase the life of the teeth.

Thus, one aspect of the invention relates to a metal card clothing comprising a separator as a projection in the tooth root which protects the root by preventing fibers from flowing into the tooth root.

Other aspects, advantages and salient features of the present invention will become apparent to those having ordinary knowledge in this technical field from the embodiments described in conjunction with the accompanying drawings, which disclose exemplary embodiments of the present invention.

801:Metal needle

802: Base

803:Leaves

804: Teeth

8041: First rising edge

8041":Rising edge

8042: Tooth root base

8043: First tooth tip

8043":The tip of the first tooth

8044: Back edge

8045: Second rising edge

8046: point

8046': point

8047: Cutting edge

8048: Back edge

9043': Second tip

9044: The back edge

1104: Tip of the first tooth

11043: Tip of first tooth

11043":Tip of the first tooth

11047: Second tooth tip

1204: Tip of first tooth

12043: Tip of first tooth

12043":Tip of the first tooth

12047: Second tooth tip

1304: Tip of first tooth

13043: Tip of first tooth

13043":Tip of the first tooth

13047: Second tooth tip

D1: Tooth height

D2, D3: Height

p: tooth spacing

The following description and accompanying drawings will provide a better understanding of the above and other features, aspects and advantages of the subject matter.

[Figures 1 to 2] illustrate the common metal card clothing.

[Figures 3 to 4] illustrate the conventional tooth profile of known metal card clothing.

[Figures 5-6] illustrate damage in the root where hardness may not have been achieved.

[Figure 7] illustrates a metal card clothing according to an embodiment of the present invention.

[Figure 8] illustrates the separator design of the metal card clothing according to an embodiment of the present invention.

[Figure 9] illustrates the separator design of the metal card clothing according to an embodiment of the present invention.

[Figure 10] illustrates the divider design in equal spacing configuration and in varying spacing configuration.

[Figure 11] illustrates a barbed wire with a separator according to an embodiment of the present invention.

[Figures 12 to 13] illustrate the presence of separators before each tooth and at random positions with different shapes in a standard tooth pattern (Figure 12) and a modified tooth pattern (Figure 13) of a metal wire according to an embodiment of the present invention.

Those having ordinary skill in the art will appreciate that the elements in the figures are illustrated for simplicity and clarity and may not be drawn to scale. For example, the size of some elements in the figures may be enlarged relative to other elements to help improve understanding of the various embodiments of the invention. Throughout the figures, it should be noted that the same reference numbers are used to depict the same or similar elements, features, and structures.

The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of the exemplary embodiments of the present invention. The following description includes various specific details to assist in that understanding, but such details are to be regarded as merely exemplary.

Therefore, those with ordinary skill in the art will recognize that various changes and modifications may be made to the embodiments described herein without departing from the scope of the present invention. In addition, descriptions of well-known structures and methods are omitted for clarity and conciseness.

The terms and phrases used in the following description and claims are not limited to the written meanings, but are used only by the inventor to achieve a clear and consistent understanding of the invention. Therefore, it should be apparent to those of ordinary skill in the art that the following description of various embodiments of the invention is provided for illustrative purposes only and not for the purpose of limiting the invention as defined by the attached claims and their equivalents.

Features described and/or illustrated with respect to one embodiment may be used in the same manner or in a similar manner in one or more other embodiments and/or in combination with or in place of features of other embodiments.

It should be emphasized that the term "comprises/comprising" (if used in this specification) specifies the presence of stated features, integers, steps or components but does not exclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

The present invention discloses a metal card clothing comprising a separator such as a protrusion at the tooth root, which prevents fibers from flowing into the tooth root as shown in Figure 7 without limitation. This design ultimately prevents tooth wear and damage and thus increases the quality life of the card clothing.

The separator protects the tooth roots from excessive wear and also acts as a separator for the fiber bundles, seed coats and inferior products by breaking and guiding the fiber bundles, seed coats and inferior products to the spaces between the points and further protecting the teeth. The separated or broken inferior products easily flow into the spaces between the wires and thus embedment problems are also minimized.

The design of the separator requires various shapes and sizes to cater to the size of the spacing and the application. Different shapes of the separator according to different embodiments of the present invention are shown in Figures 8 and 9. Tests on the implementation of the present invention have given better initial performance and longer quality life of the intended design. This invention document may indicate a specific shape and size or several shapes and sizes of the separator for the purpose of explaining and describing different embodiments, and it does not limit the scope of the present invention in any way.

Reference has been made to Figure 10 wherein the divider design follows the known standard equal spacing configuration as well as the varied spacing configuration as disclosed as an added feature in the previously granted Indian Patent No. 75/MAS/2000.

The heights D2 and D3 of the dividers in Figures 8 and 9 vary from 25% to 75% of dimension D1.

According to an embodiment of the present invention, FIG. 8 and FIG. 9 illustrate a disclosed metal needle (801) for use in a carding machine. The needle comprises a base (802) and a blade (803) formed on the base, the blade comprising teeth (804), wherein the teeth (804) comprise: a tooth spacing (p); a first rising edge (8041) having a defined profile, which transitions from a tooth root base (8042) to form a first tooth tip (8043) of a first tooth, the first tooth The first tip of the tooth comprises a tooth height D1 from the tooth root base (8042), a working angle substantially between 0° and 50° formed by the first rising edge (8041) of the first tooth tip (8043), an angle substantially between 50° and 90° formed by a rear edge (8044) of the first tooth; a second rising edge (8045) , which has a defined profile that substantially transforms from a point (8046) at the tooth root base (8042) or from a point (8046') at the rear edge (8044) of the first tooth tip to form a second tooth, the second tooth including from the point (8046) at the tooth root base (8042) or from the point (8046') at the rear edge (8044) of the first tooth tip 8046') to a height D3 of a tip (8047) of the second tooth, a height D2 from the tip (8047) of the second tooth to the tooth root base (8042), and a rear edge (8048) of a rising edge (8041") that is contoured to substantially transition from the tip (8047) of the second tooth to a subsequent first tooth tip (8043").

According to another embodiment of the present invention, the teeth of the metal needle have equal or different spacing lengths. In addition, in another embodiment, the first tip of the first tooth transforms into a substantially flat beveled edge to form a second tip (9043'), which further transforms into a rear edge (9044) of the first tooth.

In one embodiment of the present invention, the height D2 and the height D3 of the second tooth of the metal needle vary substantially between 25% and 75% of the height D1 of the first tip of the first tooth. In some embodiments, the heights D2 and D3 of the second tooth are equal.

In one embodiment of the present invention, the substantially flat beveled edge transitioning from the first tip of the first tooth to the second tip has an angle of about 2 degrees, and the substantially flat beveled edge transitioning from the first tip of the first tooth to the second tip has a length substantially between 0.3 and 0.7 mm.

In one embodiment of the present invention, the substantially arcuate edge formed by the transition from the rear edge of the first tooth to the second rising edge of the second tooth, the substantially arcuate edge formed by the rising edge of the second tooth, the tip of the second tooth and the rear edge of the second tooth, and the arcuate edge formed by the transition from the rear edge of the second tooth to the first rising edge of the subsequent first tooth have different radius sizes.

According to another embodiment of the present invention, the metal needle is a barbed wire, a cylindrical wire, and the like.

Similar separators can also be used in barbed wire applications as shown in Figure 11. The high load, higher erosion and wear characteristics are more pronounced in barbed wire applications.

Referring to Figures 11, 12 and 13, the second tooth tip (11047; 12047; 13047) of the metal needle/barbed wire is positioned alternately or once between the three first tooth tips (11043, 11043", 1104; 12043, 12043", 1204; 13043, 13043", 1304).

The presence of a divider (second tooth) before each tooth (first tooth) or at intervals of 2, 3, 4 and 5 tooth spacings as shown in Figures 12 and 13 is also possible. The divider and tooth flank are separated by a minimum gap of 0.05 mm on either side to facilitate the heat treatment process to harden the tooth root to the extent possible. In addition, the divider is also partially hardened to withstand some wear.

Based on experimental tests conducted with exemplary embodiments of metal card clothing as described above, the following table shows the improvements achieved compared to conventional profile mounted needles.

When comparing seed neps in the yarn, a significant reduction was noted with the separator tooth profile mounted needle compared to the conventional profile mounted needle. In yarn defect levels, a 21% improvement was found with the separator tooth profile mounted needle.

When tested in the same manner, a 10% improvement was noted in the separator tooth profile.

Some non-limiting advantages of the present invention are:

1. Prevent tooth damage and wear

2. Improve the life quality of metal card clothing.

Although the metal card clothing has been described in language specific to structural features, it should be understood that the embodiments disclosed in the above sections are not necessarily limited to the specific methods or devices described herein. Rather, the specific features are disclosed as embodiments of the metal card clothing.

801:Metal needle

802: Base

803:Leaves

804: Teeth

8041: First rising edge

8041":Rising edge

8042: Tooth root base

8043: The first cutting edge

8043":The tip of the first tooth

8044: Back edge

8045: Second rising edge

8046: point

8046': point

8047: Cutting edge

8048: Back edge

D1: Tooth height

D2, D3: Height

Claims (8)

A metal needle (801) for use in a carding machine, comprising: a base (802) and a blade (803) formed on the base, the blade comprising teeth (804), wherein the teeth (804) comprise a tooth spacing (p); a first rising edge (8041) having a defined contour, which transforms from a tooth root base (8042) to form a first tooth tip (8043), the first tip of the first tooth comprising: a distance from the tooth root base ( a tooth height (D1) of 0° to 50° formed by the first rising edge (8041) of the first tooth tip (8043), an angle between 50° and 90° formed by a rear edge (8044) of the first tooth; a second rising edge (8045) having a point (8046) at the tooth root base (8042) or a point (8047) at the rear edge (8044) of the first tooth tip; 46') to form a defined profile of a second tooth, the second tooth comprising: a height (D3) from the point (8046) at the tooth root base (8042) or from the point (8046') at the rear edge (8044) of the first tooth tip to a tip (8047) of the second tooth, a height (D2) from the tip (8047) of the second tooth to the tooth root base (802), and a rear edge (8048) which is profiled to extend from the first tooth tip to the rear edge (8048) of the second tooth. The tip (8047) of the second tooth transitions into a rising edge (8041") of a subsequent first tooth tip (8043"), wherein the first tip of the first tooth transitions into a flat beveled edge to form a second tip (9043'), the second tip (9043') further transitions into the rear edge (9044) of the first tooth, wherein the substantially flat beveled edge transitioning from the first tip of the first tooth to the second tip has an angle of about 2 degrees. A metal needle as claimed in claim 1, wherein the teeth have equal or different spacing lengths. A metal needle as claimed in claim 1, wherein the height (D2) and the height (D3) of the second tooth vary between 25% and 75% of the height (D1) of the first tip of the first tooth. A metal needle as claimed in claim 1 or claim 3, wherein the height (D2) and D3 of the second tooth are equal. A metal needle as claimed in claim 1, wherein the smooth beveled edge transitioning from the first tip of the first tooth to the second tip has a length between 0.3 and 0.7 mm. A metal needle as claimed in claim 1, wherein the arcuate edge formed by the transition from the rear edge of the first tooth to the second rising edge of the second tooth, the arcuate edge formed by the rising edge of the second tooth, the tip of the second tooth and the rear edge of the second tooth, and the arcuate edge formed by the transition from the rear edge of the second tooth to the first rising edge of the subsequent first tooth have different radius sizes. A metal needle as claimed in claim 1, wherein the needle is a barbed wire, a cylindrical wire or the like. The metal card clothing of claim 1, wherein the second tooth tip (11047; 12047; 13047) is positioned alternately or once between the three first tooth tips (11043, 11043", 1104; 12043, 12043", 1204; 13043, 13043", 1304).