The stationary flats in cylinder top portion of carding machine

Abstract

ABSTRACT “The stationary flats in cylinder top portion of carding machine” Carding revolving flat removes short fibers and seed coat fibers. The manmade and synthetic fibers not have short fibers, seed coat fibers, and neps. So flat waste removing is not necessary for these fibers. In this new method, revolving flat (34) is replaced by the stationary flats (11). The set of stationary flats are fixed in upper part of cylinder at both side of cylinder (9) vertical axis line (x) at least 10 degree (AO). It consist at least one knife (30) for assist in elimination of trash and dirt particles. It consist at least one suction hood (28) to transport the extracted dust, trash and micro dust. A metallic clothing (25) with plurality of sharp tooth is provided at the bottom portion of stationary flat bars (24). Fig 2

Specification

Description:FORM 2
THE PATENTS ACT 1970
(39 OF 1970)
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See Section 10 and rule 13)

1. Title of the invention :
The stationary flats in cylinder top portion of carding machine
2. Applicant(s)
(a)1. NAME : NATARAJAN KRISHNAMURTHY
2. NAME : KRISHNAMURTHY AHILA
(b) NATIONALITY : India
(c) ADDRESS : 2/11 Chitthampalam (post),
Palladam (TK),
Tiruppur DT,
641664,
Tamilnadu,
India

3. PREAMBLE TO THE DESCRIPTION :
The following specification particularly describes the invention and the manner in which it is to be performed.

The stationary flats in cylinder top portion of carding machine
FIELD OF INVENTION AND USE OF INVENTION
The aspect of the present invention broadly relates to textile machines, especially carding machines and, in particular, is concerned with the fiber opening area of cylinder and flat zone. The present invention relates to giving extra stationary flats for replacing revolving flats.
The advantage of this invention is to avoid flat waste in carding machine.
DESCRIPTION OF BACKGROUND AND PRIOR ART :
Spinning mills include various sections comprising different types of textile machines for converting natural and man-made fibers and their blends into yarns.
Carding machine currently form sliver from fibers flocks, made of multiple fibers which are first passed through a set of chute feed rollers and a chute opening roller for further opening the fiber.
The semi opened fibers go through a feed roller and at least one lickerin. Heavy materials separated in lickerin zone as a waste. The further opened fibers send to cylinder. The fibers are separated as individual fiber in between cylinder and flats. This fibers stripped by doffer. While fibers transfer from cylinder to doffer, fiber ends get bend known as hooks. The stripper or a redirecting roller strips the fiber from doffer and, send to a set of squeezing or a doffing roller then goes to a set of delivery calender roller or a delivery roller.
The fiber web is converted to sliver in the delivery calender roller or the delivery roller. The sliver is stored in a can through a set of coiler calender or a set of coiler delivery roller.
Prior art carding machines use revolving flats that move around the peripheral surface of the upper part of the carding cylinder.
Opening to individual fibers, this enables elimination of impurities from fiber and performance of other operations. Fiber opening is mainly done at cylinder and flat area. The fiber tufts are opened to form single fibers, aligned and cleaned between a clothed rotating cylinder and fixed and revolving carding elements.
Types of Flats:
1. Revolving flat
2. Stationary flat
Revolving flat ;
The "revolving flat carding" flats are the flexible wire-clothed bars rotating at a very slow speed compared with the high speed cylinder. Flats move slowly either in the same direction or in the opposite direction of the cylinder. The flat wire points are opposite to the direction of the cylinder wire points. The cylinder and the flats form the main carding zone.
Opening of tufts into individual fibers;
Elimination of remaining fiber impurities;
Elimination of some of the short fibers;
Untangling neps; dust removal
The task of the flat is creating partial longitudinal orientation of the fibers.
The bars of the flats are made of cast iron or aluminium and are somewhat longer than the operating width of the card, since they rest on adjustable flexible bends to the left and right of the main cylinder and must slide on these guide surfaces. Each bar is approximately 30 - 40 mm wide. The bars are given a ribbed form in order to prevent longitudinal bending. For this reason, the flats do not enable an absolutely continuous carding surface to be formed above the cylinder; there are gaps between the clothing strips.
Stationary flats ;
Stationary flats can be used in addition to revolving flats, an aluminium extrusion. The flange carries a card-clothing top or other operative element such as a trash extracting knife which is clipped or attached by screws to the surface of the flat, and the rib is designed to support the flat correctly across the width of the carding cylinder. The ends of the flat are machined to accept the setting and securing arrangements for fixing the flat to the carding machine frame in its required relationship to the carding cylinder.

The drawbacks in the existing arrangements is that :
1. Only the smaller number of the revolving flats is in the working zone. The revolving flat card needs a large number of flats that are ineffectively used, cause high costs and do not contribute to the carding process.
2. A better carding effect is obtained with rougher flat clothing's at the beginning and with finer flat clothing's toward the end of the main carding zone, which is not possible with revolving flats.
3. The flexible bend, an important and expensive part of the revolving flat carding, and the flats themselves suffer from considerable wear and tear which causes high maintenance costs.
4. The revolving flat card requires a complicated construction for driving, guiding and cleaning which induces high costs for manufacturing and maintaining this type of card.
5. Manmade or synthetic fibers are not having short fibers and seed coat fibers. So flat waste removing is not required for these fibers.
Due to the aforementioned drawbacks, more good fibers go to waste as flat waste. The present invention provides the stationary flats instead of revolving flats in carding machine, for eliminating the above drawbacks.

OBJECTS OF THE INVENTION
The principle object of this invention is, to avoid flat waste in carding machine. There are no short fibers, dust, neps and seed coat fibers in manmade and synthetic fibers. So, in this fibers no need of flat waste removal.
It is another object of this invention is, a simple general design and construction are therefore possible, which results in lower manufacturing and maintaining costs.
It is another object of this invention is, fewer flats are needed in comparison to the revolving flat card. All the flats can be permanently used.
It is yet another object of this invention is, there is no motion of the bars of the stationary flats on the flexible bend, therefore wear and tear of those elements are avoided.
It is yet another object of this invention is, no supplementary flat cleaning devices outside the main carding zone are necessary.
It is another object of this invention is, the flat clothing's can be adjusted to their position in the main carding zone. Rougher clothing's might be positioned at the beginning and finer clothing's toward the end of the main carding zone.
It is another object of this invention is, the flat position relative to the main cylinder can be individually set, thus additionally optimising the carding quality.

SUMMARY OF THE INVENTION
According to the present invention the stationary flats in cylinder top portion of carding machine is provided comprising a set of chute feed rollers and an opening roller for opening a fiber tuft; a feed roller and at least one Licker-in to open and clean the feed material; a cylinder and a set of Flats, to open the feed material as individual fiber; a set of stationary flats above the lickerin, and an another set of stationary flats above a doffer for further opening the fiber; the doffer for removing the fiber from cylinder and it gives to a redirecting roller or stripper roller; a set of crushing or squeezing rollers to form the individual fibers as a web; a delivery calender roller or delivery roller for convert web to sliver; a coiler unit for store the sliver in can; wherein said carding machine further included the stationary flats in the upper part of the carding cylinder.
According to another embodiment of the present invention, the set of stationary flats are fixed at both side of cylinder vertical axis line at least 10 degree.
According to another embodiment of the present invention, the set of stationary flats consist at least one knife for assist in elimination of trash and dirt particles.
According to another embodiment of the present invention, the set of stationary flats consist at least one suction hood to transport the extracted dust, trash and micro dust.
According to another embodiment of the present invention, a metallic clothing (25) with plurality of sharp tooth is provided at the bottom portion of stationary flat bars (24).
According to another embodiment of the present invention, the set of stationary flats are non rotatable and these are fixed on a set of side supporting frames.
According to another embodiment of the present invention, the setting between the individual stationary flats and the cylinder is adjustable.
According to another embodiment of the present invention, the points per square inch (PPSI) of stationary flats wire points, increases from lickerin side to doffer side; Less PPSI in above lickerin (10), Medium PPSI in above cylinder (11), and more PPSI in above doffer (12). A better carding effect is obtained with rougher flat clothing's at the beginning and with finer flat clothing's toward the end of the main carding zone.
According to another embodiment of the present invention, the stationary set of flats consist at least one plain flat without wire points for guide the fibers.
According to another embodiment of the present invention, a spring loaded arrangement is provided to avoid any damages to wire clothing.

BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings constitute a part of the description and are used to provide further understanding of the present invention. Such accompanying drawings illustrate the embodiments of the present invention which are used to describe the principles of the present invention together with the description.
Figure 1 illustrates schematic view of a prior art of the carding machine.
Figure 2 illustrates schematic view of the textile carding machine with the stationary flats in the upper part of the carding cylinder according to embodiment of the present invention.
Figure 3 illustrates schematic view of the position of stationary flats with respect to cylinder vertical axis according to another embodiment of the present invention.
Figure 4 illustrates schematic view of a metallic clothing with plurality of sharp tooth is provided at the bottom portion of stationary flat bars according to another embodiment of the present invention.
Figure 5 illustrates schematic view of the plain flat without wire points according to another embodiment of the present invention.
Figure 6 illustrates schematic view of the suction hoods with knife according to another embodiment of the present invention.
Figure 7 illustrates schematic view of the spring load arrangement for stationary flats with metallic wire points according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
This invention is illustrated with the help of the accompanying drawings;
Accordingly, the present invention provides the stationary flats in cylinder top portion of carding machine, will avoid flat wastes for manmade and synthetic fibers. The embodiments of the present invention are described by referring to the figures of the accompanying diagrams.
The set of stationary flats (11) consist :
a. At least one flat with metallic clothing (24) and/or
b. At least one flat with plain working place (26) and/or
c. At least one suction hood (28) and/or
d. At least one knife or sharp edge (30)

The invention may be better understood, when considered in view of the following detailed description of exemplary embodiments, taken with the accompanying drawings. These embodiments describe only a few of the various ways in which the principles of various other embodiments maybe realized and the described embodiments are intended to include all such embodiments and their equivalents and the reference numerals used in the accompanying drawings correspond to the like elements throughout the description.
FIG 1 illustrates the carding machine known in the existing art. Carding machine (1) currently form sliver (21) from semi opened fibers (2), made of multiple fibers which are first passed through a set of chute feed rollers (3) and a chute opening roller (4) for further opening the fiber (2).
The semi opened fibers go through a feed roller (7), feed plate (6) and at least one lickerin (8). Heavy materials separated in lickerin zone as a waste. While material is fed in a carding machine, first the licker in roller takes small tufts of fibers from the feed rollers. These small tufts of fibers gets transferred to main cylinder clothed with finer wire points by stripping action. Hence the fiber tuft gets distributed on a higher number of wire points to facilitate intensive carding action between main cylinder and flat tops wire points. A set of pre opening stationary flats (10) further open the fibers. Pre opening stationary flat clothing is designed to improve the opening of fibers in the pre-opening zone before they enter the carding zone, preventing unopened flakes from causing problems in the pre-carding zone. The bulk of fibers are separated as individual fiber in between cylinder and flats (34). A set of post opening stationary flats (12) further open the fibers and micro dusts removed through suction hoods. The tooth design ensures that fibers are perfectly parallelized in the post-carding zone, delivering a smooth transfer to the doffer and creating superior quality yarn, for longer. This fibers stripped by doffer (13). While fibers transfer from cylinder to doffer, fiber ends get bend known as hooks. A stripper or a redirecting roller (14) strips the fiber from doffer and, send to a set of squeezing or a doffing roller (15 & 18) then goes to a set of delivery calender roller or a delivery roller (16 & 19). In between the squeezing roller and the delivery roller either a set of cross apron mounted or not mounted. The remaining attached fibers in doffer are stripped by a stripper brush roller (17).
The fiber web (29) is converted to sliver (21) in the delivery calender roller or the delivery roller. The sliver is stored in a can (23) through a set of coiler calender or a set of coiler delivery roller (22). A guide roller (20) is guide the sliver goes from delivery calender to coiler calender roller.
The wire points in Main Cylinder and flat tops are opposite. Hence it performs carding action. For performing a good carding action it is preferred the cylinder should rotate at high speed i.e. with a high surface speed while the revolving flats move at a lower surface speed.

Stationary flats are a component of carding machines that are fixed to the main frame and do not move. They are used to open large fiber tufts into smaller ones in the pre-carding zone, and to parallelize and individualize the fibers in the post-carding zone. Stationary flats, specifically in the pre-carding area, are exposed to maximum stresses which can lead to disproportionate clothing wear. To ensure an even gap between cylinder and stationary flat, allowing optimum opening of the raw material lumps.

The carding quality is primarily determined in the cylinder region, where the revolving flat is of high importance. With an optimal number of flat bars, it is responsible for cleaning as well as extracting neps and short fibers.
Opening the fibers before the main carding process prevent overloading and damages in the flat top area. Stationary flats above the doffer have more PPSI and further parallelize the opened fibers.
This invention is illustrated with the help of the accompanying drawings; Fig 2 shows schematic view of position of the stationary flats in cylinder top portion of carding machine, according to the present invention. The stationary flats (11) are fixed at the upper part of the carding cylinder (9).
The primary objective of a carding machine is to separate the individual fibers from fiber tuft which is performed between the main cylinder and flats. There is no short fiber, neps, seed coat fibers and dust in manmade and synthetic fibers. So there is no need of flat waste removal for manmade and synthetic fibers. Fiber opening is the main objective of manmade and synthetic carding machine. So prior art of carding machine revolving flats (34), are replaced by the stationary flats (11).
This invention is illustrated with the help of the accompanying drawings; Fig 3 shows schematic view of the position of stationary flats with respect to cylinder vertical axis according to another embodiment of the present invention. The stationary flats are provided both side of cylinder vertical axis (x), at least 10 degree. There are no revolving flats in the new method.
This invention is illustrated with the help of the accompanying drawings; Fig 4 shows schematic view of metallic clothing with plurality of sharp tooth is provided at the bottom portion of stationary flat bars. A closer setting 0.2 to 0.5 mm is maintained between stationary flat wire points and cylinder wire points. Due to higher cylinder speed and closer setting, the fiber tuft is opened as individual fiber.
Self cleaning of the flats is achieved by the card wind in the sealed chamber of the whole main carding zone and by the replacement of the steel wire clothing of the flats with a non loading, rigid, abrasive granular surface.
Modern textile carding machines are furnished with different carding elements, both stationary and revolving flats. The primary carding action may take place between the carding cylinder and flats. The fibers carried by the cylinder wire tend to move toward the flats which may resist fiber movement initially, and then allow the fibers to float between the flats and the cylinder wire. This carding action may separate individual fibers, opens entangled fibers, separates and retains the neps or trash particles in the flats and finally orients the fibers in the direction of the cylinder movement.
This invention is illustrated with the help of the accompanying drawings; Fig 5 shows schematic view of the plain flat without wire points.
This invention is illustrated with the help of the accompanying drawings; Fig 6 shows schematic view of the suction hoods with knife.
This invention is illustrated with the help of the accompanying drawings; Fig 7 shows schematic view of the spring load arrangement for stationary flats with metallic wire points. If any thick material is come, stationary flats (11) come out from cylinder wire through guide rod (33) and a set of spring (32).
The air flow is of great importance for the stationary flat (11) function. The supply air is sucked by the suction hood (28) through the supply air channel. The supply air (35) is then accelerated by the nozzle effect in the narrowed passage between the flat metallic clothing section (25) and the clothing on the surface of the cylinder. This acceleration of the air stream at the passage reinforces the removing effect of the air stream to dust, trash and short fibers which are subsequently separated from the good fibers. The good and usable fibers remain in the cylinder clothing while trash and dust are removed by the acute angled edge of the knife (30).
The present invention avoids the drawbacks of the revolving flat system and offers full use of the inherent advantages. The invented flat system makes optimum use of the card wind, the fast moving air stream induced by the clothing of the main cylinder. Beside excellent carding quality the system offers a very effective extraction of trash and dust, the system being readily adjustable to the specific needs of a mill. In addition the invention gives an economical solution for manufacturing and setting the flat system. The necessarily accurate settings of the flats are easily achieved which is of considerable help in mill practice. The design uses standard card parts to a large extent, which reduces manufacturing costs.

, Claims:We claim,
1. The stationary flats in cylinder top portion of carding machine (1), comprising :
A set of chute feed rollers (3) and an opening roller (4) for opening a fiber tuft (2);
A feed roller (7) and at least one Licker-in (8) to open and clean the fiber;
A cylinder (9) and a set of Flats (34), to open the feed material as individual fiber;
A set of stationary flats (10) above the lickerin, and an another set of stationary flats (12) above a doffer (13) for further opening the fiber;
The doffer (13) for removing the fiber from cylinder and it gives to a redirecting roller or stripper roller (14)
A set of crushing or squeezing rollers (15, 18) to form the individual fibers as a web (29);
A delivery calender roller or delivery roller (16, 19) for convert web to sliver (21);
A coiler unit for store the sliver in can (23);
characterized in that
said carding machine (1) further included the set of stationary flats (11) in the upper part of the carding cylinder (9).
2. The stationary flats in cylinder top portion as claimed in 1, wherein the set of stationary flats (11) are fixed in upper part of cylinder at both side of cylinder (9) vertical axis line (x) at least 10 degree (AO); The cylinder vertical axis (x) and cylinder horizontal axis (y) are passes through cylinder centre point (36) and between both axis angle is 90 degree.
3. The stationary flats in cylinder top portion as claimed in 1 or 2, wherein the set of stationary flats (11) consist at least one knife (30) for assist in elimination of trash and dirt particles.
4. The stationary flats in cylinder top portion as claimed in any of the preceding claims, wherein the set of stationary flats (11) consist at least one suction hood (28) to transport the extracted dust, trash and micro dust.
5. The stationary flats in cylinder top portion as claimed in any of the preceding claims, wherein a metallic clothing (25) with plurality of sharp tooth is provided at the bottom portion of stationary flat bars (24).
6. The stationary flats in cylinder top portion as claimed in any of the preceding claims, wherein the set of stationary flats (11) are non rotatable and these are fixed on a set of side supporting frames.
7. The stationary flats in cylinder top portion as claimed in any of the preceding claims, wherein the setting between the individual stationary flats (11) and the cylinder (9) is adjustable.
8. The stationary flats in cylinder top portion as claimed in any of the preceding claims, wherein the points per square inch (PPSI) of stationary flats wire points, increases from lickerin side to doffer side; Less PPSI in above lickerin (10), Medium PPSI in above cylinder (11), and more PPSI in above doffer (12); A better carding effect is obtained with rougher flat clothing's at the beginning and with finer flat clothing's toward the end of the main carding zone.
9. The stationary flats in cylinder top portion as claimed in any of the preceding claims, wherein the set of stationary flats consist at least one plain flat (26) without wire points for guide the fibers.
10. The stationary flats in cylinder top portion as claimed in any of the preceding claims, wherein a spring (32) loaded arrangement to avoid any damages to wire clothing.
Dated this 12 November, 2024 NATARAJAN KRISHNAMURTHY
APPLICANT

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