EP3268517B1

EP3268517B1 - Device for overlapping, crossing, and transferring textile fibres, and method thereof

Info

Publication number: EP3268517B1
Application number: EP15738990.9A
Authority: EP
Inventors: Roberto PARLAMENTO
Original assignee: Nuova Cosmatex Srl
Current assignee: Nuova Cosmatex Srl
Priority date: 2015-03-09
Filing date: 2015-06-10
Publication date: 2021-08-04
Anticipated expiration: 2035-06-10
Also published as: WO2016189360A1; EP3268517A1; ES2893400T3

Description

Technical field

The present invention relates to a device for overlapping, crossing and transferring textile fibres, as well as to a related process. The invention also relates to an innovative carding set and an innovative carding method.

Background art

In the textile industry, a need is felt for overlapping a number of thin layers of fibres for the purpose of creating a homogeneous fibre layer having qualities such as, for example, homogeneity and constant thickness, volume and density. It also appears to be advantageous to carry out a step of crossing such textile fibres while making said thicker layer, e.g. in order to improve its tensile strength.
This process turns out to be useful, for example, for preparing a high-quality layer to be subjected to further processing steps in the textile industry.
A need is also felt, therefore, for machinery capable of carrying out such operations in an efficient and reliable manner.
WO 02/059405 A2 discloses an apparatus for producing layers from rock fibers and similar insulating materials consisting of a conveyor of the collection chamber, a receiving conveyor, at least two pairs of vertical oscillating belts, at least one feeding conveyor, and at least one deposit conveyor. The fibers are transported by the conveyor to the receiving conveyor, which then carries them into nip formed by the first pair of vertical oscillating belts, which in turn, deposit the fibers in a zigzag onto the first feeding conveyor, from where they pass between the second pair of vertical oscillating belts, which deposit them in a zigzag onto the first deposit conveyor, wherein the zigzag deposition may be repeated so that the layer of fibers entering the hardening chamber consists of two or more transversally deposited layers, laid at an angle of 90 DEG relative to each other.

Summary of the invention

It is one object of the present invention to provide a device for overlapping, crossing and transferring textile fibres, which can be produced in a simple and economical manner.
In particular, one of the advantages of the present invention is the possibility of obtaining a high-quality layer of overlapped and crossed fibres, while ensuring high productivity. Constant thickness and density can also be ensured throughout the obtained fibre mattress.
It is a further object of the invention to provide a process for overlapping, crossing and transferring textile fibres, which can conjugate product quality with productivity.
According to the present invention, this and other objects are achieved through a device and a process having the features set out in the appended independent claims.
It is to be understood that the appended claims are an integral part of the technical teachings provided in the following detailed description of the invention. In particular, the appended dependent claims define some preferred embodiments of the present invention, which include some optional technical features.

Brief description of the drawings

Further features and advantages of the present invention will become apparent from the following detailed description, which is supplied by way of non-limiting example with particular reference to the annexed drawings, wherein:

Figure 1 is a schematic perspective view of a first variant according to the present invention.

Detailed description of the invention

The device of the invention comprises:

a first conveyor belt T1 for transporting an input layer of textile fibres;
a setting-out device 10 for receiving the textile fibres from said first conveyor belt T1 and depositing them on a second conveyor belt T2, said setting-out device 10 being susceptible of moving in a reciprocating motion along a direction x.

Setting-out device 10 essentially carries out a folding operation, and is also called "translating folding cart" or "folding element".
The second conveyor belt T2 is adapted to move the textile fibres along a direction y, belonging to a plane perpendicular to said direction x, in a forward-backward reciprocating motion, wherein, in the total motion, the forward component is much greater than the backward component, for the purpose of producing a flow, in particular a continuous flow, of overlapped textile fibres.
A final transportation system is also comprised for carrying away the flow of textile fibres previously overlapped and crossed. It must be pointed out that the flow of fibres exiting the device of the invention is formed by fibres that have been overlapped and crossed by means of the present device. In other words, the output flow of fibres forms a "mattress" of fibres that have been previously overlapped and crossed.
Preferably, the device, in particular the final transportation system, includes:

a final conveyor belt T4 for receiving and transporting said flow of textile fibres parallel to said direction x;
an overturning unit T3 capable of receiving the flow of textile fibres exiting said second conveyor belt T2, and adapted to overturn them in order to lay them on said final conveyor belt T4.

Figure 1 shows some straight arrows indicating the direction along which the respective component or a part thereof moves. With particular reference to the illustrated example, directions x and y (and y1, see below) are mutually orthogonal when viewed from above.
Conveyor belt T1 shown in Figure 1 receives the thin input layer of fibres and transports them along a line of action which is parallel to direction x, in particular towards the right-hand part of the figure. Said conveyor belt T1 comprises a rolling surface 14 supported by at least one pair of rollers 16 capable of rotating. For example, one of such rollers 16 is a drive roller and the other one is a driven roller. As an alternative, both rollers 16 are drive rollers. As will be apparent to a man skilled in the art, conveyor belt T1, as well as the second conveyor belt T2 and final conveyor belt T4, can be implemented by including elements which are per se known, such as intermediate support rollers, or support surfaces, ensuring a sufficiently straight transportation surface, etc.
Rolling surface 14 of conveyor belt T1 is conveniently a substantially continuous surface, e.g. a band-like surface. As an alternative, said rolling surface 14 comprises a succession of mutually constrained links or plates forming a rolling surface capable of supporting and transporting the fibres; in other words, rolling surface 14 may be similar to a track or a tapis roulant. The same also applies to conveyor belts T2 and T4.
Setting-out device 10 receives the fibres from the first conveyor belt T1 and, as it moves, it arranges the fibres along the line of action x. In particular, setting-out device 10 translates in a reciprocating motion along said direction x.
Preferably, setting-out device 10 comprises a pair of rotary cylinders (designated by number 10) susceptible of rotating about respective axes of rotation perpendicular to direction x, and susceptible of translating in a reciprocating motion parallel to said direction x. The flow of fibres must pass through said rotary cylinders 10. Rotary cylinders 10 translate simultaneously in a reciprocating motion along direction x; in other words, they translate as a pair (in the illustrated example they translate to the right and to the left). The reciprocating motion of setting-out device 10 causes the input textile fibres to overlap, thus overlapping multiple folds of the layer of fibres on the second conveyor belt T2. In Figure 1, letter F designates a flow of fibres coming from the first conveyor belt T1 and directed towards rotary cylinders 10.
The second conveyor belt T2 comprises rolling surface 12, which moves in a forward-backward reciprocating motion (along direction y), wherein, in the total motion, the forward component is much greater than the backward component, for the purpose of producing a flow of overlapped textile fibres at the exit of conveyor belt T2. In other words, rolling surface 12 rotates alternately forwards and backwards. As a whole, the forward motion of the part of rolling surface 12 that is in contact with the fibres is greater than the backward motion of the same part of rolling surface 12. For example, rolling band 12 goes forwards by 10 cm and then backwards by 9 cm; the result is a 1cm advance at every forward-backward cycle of the reciprocating motion of the second conveyor belt T2. The part of rolling surface 12 which is in contact with the fibres is the upper one, since the fibres come from setting-out device 10, which is arranged on top of the second conveyor belt T2.
Therefore, while setting-out device 10 arranges the fibres on the second conveyor belt T2 and overlaps them in a reciprocating motion along x, the second conveyor belt T2 moves such fibres in a forward-backward reciprocating motion perpendicular to x (i.e. along y). In this way, the fibres are overlapped and crossed. Conveniently, the fibres are overlapped and crossed according to a variable-angle diagonal, depending on the travel and speed of conveyor belt T2. One advantage offered by the invention is the possibility of working continuously, receiving an input flow of fibres and producing a continuous output flow of overlapped and crossed fibres. Thus, for example, the output flow of fibres can be controlled by the taker-in cylinders of any machine located downstream of the whole device described herein.
Preferably, direction x is horizontal. Conveniently, rolling surface 12 of the second conveyor belt T2 is prevalently arranged in a horizontal plane; in other words, the second conveyor belt T2 is horizontal. In particular, rolling surface 14 of the first conveyor belt T1 is prevalently arranged in a horizontal plane; in other words, the second conveyor belt T1 is horizontal. Conveniently, also the final conveyor belt T4 is horizontal.
The final conveyor belt T4 carries the fibres along a line of action parallel to said line of action x. In this manner, the direction of the flow of textile fibres, previously overlapped and crossed to form a substantially homogeneous mattress, exiting from T4 is substantially parallel to the direction of the flow of fibres moving on T1.
Conveniently, rolling surface 12 of said second conveyor belt T2 comprises a plurality of apertures; and the device comprises suction means capable of sucking air through at least a part of said plurality of apertures. Such apertures may be, for example, holes or slots on rolling surface 12. Or, if rolling surface 12 is provided by means of links or plates, the apertures may consist of the interstices between such links or plates.
The suction means suck air from the outer surface of rolling surface 12 (i.e. the one intended to come in contact with the textile fibres) towards the inner one, in order to keep the layer of textile fibres in adherence to rolling surface 12, in particular to the outer surface thereof. This minimizes the risk that the fibres might slide on surface 12, thus avoiding the resulting adverse effects on the production of overlapped fibres.
For example, the suction means comprise one or more suction mouths arranged in the inner part of the rolling surface, and located in proximity to said apertures, for the purpose of creating said aerodynamic sucking effect. Conveniently, the suction mouths are only directed towards that part of rolling surface 12 which is intended to come in contact with the fibres, i.e. the part facing upwards. In this manner, when the fibres are on the upper support plane of rolling surface 12, as they are being subjected to the action of setting-out device 10 and to the action of rolling surface 12, they are kept in adherence to rolling surface 12 due to the suction effect; instead, when the fibres reach the end of the second conveyor belt T2, which is not provided with suction means, the overlapped fibres, which were previously held, are now free to come off and fall down onto overturning unit T3. In fact, at the ends of the second conveyor belt T2 there are respective rollers, designated by number 18.
With reference to the preferred example illustrated herein, the first conveyor belt T1 is arranged at the top. The second conveyor belt T2 is arranged under the first conveyor belt T1. Overturning unit T3 is arranged under the second conveyor belt T2. Final conveyor belt T4 is arranged under overturning unit T3. This aspect can be advantageous when, for example, other processing steps are to be carried out downstream of the device of the invention, since such processing steps can be carried out by using machines arranged longitudinally.
Preferably, overturning unit T3 includes a third rolling transportation surface, capable of transporting the flow of overlapped and crossed fibres along a direction y1 belonging to a plane perpendicular to said direction x, and having an oblique end side 20, inclined by approx. 45° relative to said direction y1, on which said rolling surface slides. Therefore, the third rolling transportation surface (in particular, when viewed from above) is essentially shaped like a rectangular trapezoid, the oblique side 20 being the inclined side thereof.
In particular, the third rolling transportation surface of overturning unit T3 is prevalently arranged in a horizontal plane; in other words, the third rolling transportation surface is horizontal. The upper part of the third rolling surface is intended to receive the overlapped and crossed textile fibres from the second conveyor belt T2.
In the preferred embodiment illustrated herein, the third rolling surface comprises:

a drive cylinder 22, conveniently rotated by a drive unit;
a plurality of idle pulleys p1, p2, ..., pn forming said oblique end side 20;
a belt 24 movably connected to said drive cylinder 22 and said plurality of idle pulleys p1, pn; said belt 24 provides the third rolling surface.

Pulleys p1, pn are aligned to form oblique side 20. Therefore, drive cylinder 22 is the height of said rectangular trapezoid. Therefore, oblique side 20 is inclined relative to drive cylinder 22, in particular by 45°.
Belt 24 is tightened between drive cylinder 22 and pulleys p1, pn. In particular, belt 24 moves, when it is in the upper part of the third rolling surface, in the direction indicated by the arrow y1, i.e. from drive cylinder 22 towards the first pulley p1. Then, starting from the first pulley p1, belt 24 returns towards drive cylinder 22, running along the lower part of the third rolling surface. Then belt 24 returns towards the second pulley p2, and so on until the last pulley pn. Belt 24 exiting the last pulley pn returns, through suitable transmission means, to the initial end of drive cylinder 22 to restart its cycle, i.e. to run towards the first pulley p1. In the illustrated example, said transmission means include a plurality of idle pulleys (in particular three pulleys, designated r1, r2, r3).
Conveniently, the outer surface of drive cylinder 22 comprises a plurality of grooves. In such grooves belt 24 slides in a guided manner, so that belt 24 will stay in the predetermined positions throughout the length of drive cylinder 22.
In accordance with an alternative variant, the third rolling transportation surface of overturning unit T3 comprises a plurality of belts, wherein each belt is adapted to move in a rolling motion between drive cylinder 22 and a respective idle pulley belonging to said plurality of idle pulleys p1, p2, ..., pn. In this case as well, the outer surface of drive cylinder 22 comprises a plurality of grooves, wherein a respective belt is adapted to run in each groove.
After the fibres have been overlapped and crossed on the second conveyor belt T2 (thus forming a sort of mattress), they fall onto the third rolling transportation surface of overturning unit T3, in the proximity of drive cylinder 22; then they are carried towards oblique side 20. At this point, the fibres will fall, on the oblique side 20, onto the final conveyor belt T4. Oblique side 20 allows the fibres that are moving along y1 on the third rolling transportation surface to be overturned and placed onto the final conveyor belt T4, which moves parallel to x. In practice, thanks to said oblique side 20, the fibres are overturned by substantially 90°, in that direction y1 is substantially perpendicular, when viewed from above, to direction x.
The device comprises motor means adapted to impart a drive force to at least one of: the first conveyor belt T1, setting-out device 10, the second conveyor belt T2, overturning unit T3, final conveyor belt T4. There may be a plurality of motor means, each one for imparting drive force to a respective component of the invention. As an alternative, there may be a single motor means for imparting drive force to different components of the invention through suitable transmission means.
Preferably, the device comprises a control unit for controlling and coordinating at least the operation of said first conveyor belt T1, said setting-out device 10, said second conveyor belt T2, according to criteria that may be predefined or selected by a user. Conveniently, the control unit also coordinates the operation of overturning unit T3 and of final conveyor belt T4. Conveniently, the control unit coordinates the operation of the motor means.
For example, the user can modify at will some operating settings, including, for example, the transportation speed of T1, T2, and conveniently also of T3 and T4, the translation speed (and possibly also the rotation of rotary cylinders 10) of setting-out device 10.
For example, it is possible to set the desired number of overlapped layers; as aforementioned, the overlapping of the fibre layers is carried out thanks to the cooperation between setting-out device 10 and the second conveyor belt T2. Conveniently, running speed of T2 is equal to the transportation speed of T1 divided by the desired number of overlaps. Merely by way of example, one may set: transportation speed of T1 equal to 60 metres/minute, desired number of overlaps equal to 40, running speed of T2 equal to 60:40=1.5 metres/minute. Of course, many other parameters can also be set, depending on various factors, such as required productivity, type of treated fibres (e.g. wool, cotton, synthetic, artificial, metallic, aramidic, etc.), required number of overlaps, average travel of T2, etc.
The present invention also relates to a carding set comprising:

a crossing and blending device for textile fibres according to the invention;
a first carding machine (not shown) arranged upstream of said device, with reference to the flow of textile fibres;
a second carding machine (not shown) arranged downstream of said device, with reference to the flow of textile fibres.

Preferably, the carding set prevalently extends longitudinally, parallel to the axis x, and comprises overturning unit T3 and final conveyor belt T4.
In accordance with the present invention, it is possible to provide a process for overlapping textile fibres, comprising the steps of:

a. creating an input flow of textile fibres;
b. taking and overlapping the flow of fibres on a conveyor belt T2, moving said flow of fibres along a direction x in a reciprocating motion by means of a setting-out device 10;
c. moving the flow of fibres, by means of said conveyor belt T2, along a direction y, belonging to a plane perpendicular to said direction x, in a forward-backward reciprocating motion, wherein, in the total motion, the forward component is much greater than the backward component, for the purpose of producing a flow of overlapped and crossed textile fibres;
d. creating an output flow of textile fibres.

Conveniently, the process is carried out by means of a device as illustrated and described in the above description, to which reference should be made for a better understanding and for brevity.
Preferably, step d includes the step of:
e. overturning the flow of overlapped and crossed textile fibres and laying them on a transportation means capable of transporting them parallel to said direction x.
Preferably, step c includes the step of:
f. sucking air through at least a part of a plurality of apertures provided on said conveyor belt T2, for keeping the layer of textile fibres in adherence to said conveyor belt T2.
Furthermore, in accordance with the present invention it is possible to provide a process for carding textile fibres, comprising the steps of:

carrying out a first carding;
carrying out a process for overlapping and crossing textile fibres according to the invention;
carrying out a second carding.

In particular, this innovative carding process can be carried out on fibres such as: wool, cotton, synthetic, artificial, metallic, aramidic, etc.
Of course, without prejudice to the principle of the invention, the forms of embodiment and the implementation details may be extensively varied from those described and illustrated herein by way of non-limiting example, without however departing from the scope of the invention as set out in the appended claims.

Claims

Device for overlapping, crossing and transferring textile fibres, comprising:
- a first conveyor belt (T1) for transporting an input layer of textile fibres;

- a setting-out device (10) for receiving the textile fibres from said first conveyor belt (T1) and depositing them on a second conveyor belt (T2), said setting-out device (10) being configured for moving in a reciprocating motion along a first direction (x);
said second conveyor belt (T2) being adapted to move the textile fibres along a second direction (y), belonging to a plane perpendicular to said first direction (x), in a forward motion, for the purpose of producing a flow of overlapped and crossed textile fibres;

- a final transportation system for carrying away the flow of textile fibres previously overlapped and crossed;
characterized in that said second conveyor belt (T2) is configured to perform a forward-backward reciprocating motion, wherein, in the total motion of said forward-backward reciprocating motion, the forward component is much greater than the backward component.
Device according to claim 1, wherein the final transportation system comprises:
- a final conveyor belt (T4) for receiving and transporting said flow of textile fibres previously overlapped and crossed, parallel to said first direction (x) ;

- an overturning unit (T3) capable of receiving the flow of textile fibres exiting said second conveyor belt (T2), and adapted to overturn them in order to lay them on said final conveyor belt (T4).
Device according to claim 1 or 2, wherein a rolling surface (12) of said second conveyor belt (T2) comprises a plurality of apertures; and wherein said device for overlapping, crossing and transferring textile fibres further comprises suction means capable of sucking air through at least a part of said plurality of apertures.
Device according to claim 2 or 3, wherein said first conveyor belt (T1) is arranged at the top; said second conveyor belt (T2) is arranged under said first conveyor belt (Tl); said overturning unit (T3) is arranged under said second conveyor belt (T2); said final conveyor belt (T4) is arranged under said overturning unit (T3).
Device according to any one of claims 2 to 4, wherein said overturning unit (T3) includes a third rolling transportation surface, capable of transporting the flow of fibres along a third direction (y1) belonging to a plane perpendicular to said first direction (x), and having an oblique end side (20), inclined by 45° relative to said third direction (y1), on which said third rolling transportation surface slides.
Device according to claim 5, wherein said third rolling surface comprises:
- a drive cylinder (22);

- a plurality of idle pulleys (p1, p2, pn) forming said oblique end side (20);

- a belt (24) movably connected to said drive cylinder (22) and said plurality of idle pulleys (p1, p2, pn), said belt (24) forming, at least partly, said third rolling transportation surface.
Device according to any one of the preceding claims, wherein said setting-out device (10) comprises a pair of rotary cylinders configured for rotating about respective axes of rotation parallel to said second direction (y), and configured for translating in a reciprocating motion along said first direction (x); the flow of fibres being intended to run between said rotary cylinders.
Device according to any one of claims 2 to 7, comprising a control unit for controlling and coordinating at least the operation of said first conveyor belt (T1), said setting-out device (10), said second conveyor belt (T2), according to criteria that are predefined or selected by a user.
Carding set comprising:
- an overlapping, crossing, and transferring device for textile fibres according to any one of claims 1 to 8;

- a first carding machine arranged upstream of said device, with reference to the flow of textile fibres;

- a second carding machine arranged downstream of said device, with reference to the flow of textile fibres.
Process for overlapping textile fibres, comprising the steps of:
- creating an input flow of textile fibres;

- taking and overlapping the flow of fibres on a conveyor belt (T2) by moving said flow of fibres along a first direction (x) in a reciprocating motion by means of a setting-out device (10);

- moving the flow of fibres, by means of said conveyor belt (T2), along a second direction (y), belonging to a plane perpendicular to said first direction (x), in a forward-backward reciprocating motion, wherein, in the total motion, the forward component is much greater than the backward component, for the purpose of producing a flow of overlapped and crossed textile fibres;

- creating an output flow of textile fibres.
Process according to claim 10, wherein step of creating an output flow of textile fibres includes the step of:
- overturning the flow of overlapped textile fibres and laying them on a transportation means capable of transporting them parallel to said first direction (x).
Process according to claim 10 or 11, wherein step of moving the flow of fibres includes the step of:
- sucking air through at least a part of a plurality of apertures provided on said conveyor belt (T2), for keeping the layer of textile fibres in adherence to said conveyor belt (T2).
Process for carding textile fibres, comprising the steps of:
- carrying out a first carding;

- carrying out a process for overlapping textile fibres according to any one of claims 10 to 12;

- carrying out a second carding.