DESC:FIELD
The present invention relates to rollers of carding machines.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
In a revolving flat carding machine, the process of separating individual fibres (also known as the carding process) takes place between the wire points of rollers and wire points of flat tops. Conventionally, all rollers and clearer cards of the carding machine are mounted with metallic wires. Fibre tufts are fed into the carding machine through a licker-in, and transferred to the cylinder configured to rotate at a high speed, which may go up to 600 RPM, to induce the carding effect. At the same time, the high speed of the cylinder creates a huge air current around it. The cylinder wire points carry the tufts, and pass it through the flat bar wire points, to clean the fibres and remove any impurities. The cleaned fibres are then carried by the cylinder wire points and taken out by doffer of the carding machine. Similar actions are done in the roller and clearer card between a set of worker rollers and cylinder roller clothed with metallic wire.
During processing of fibres through roller and clearer cards it is essential that fibres are evenly opened for which the wire points should be distributed evenly on the rollers. However, while processing fibres of variable cut lengths through the wire mounted rollers of the carding machine for opening the fibres, it is necessary the opening action is gently done by the wire mounted rollers, with an improved carding efficiency during processing of variable cut length fibre.
There is therefore felt a need for a roller of a carding machine mounted with a type of metallic wire that alleviates the aforementioned drawbacks.

OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a wire for a roller of a carding machine.
Another object of the present disclosure is to provide a wire for a roller which efficiently transfers fibres therefrom.
Yet another object of the present disclosure is to provide a wire for a roller which has variable wire point patterns with areas of highly efficient fibre transference zones.
Still another object of the present disclosure is to provide a wire for a roller which has relatively reduced chances of fibre rupture.
One object of the present disclosure is to provide a wire for a roller which increases the carding effect with uniform web quality.
Another object of the present disclosure is to provide a wire for a roller which increases the productivity of the carding machine.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a wire for a roller of a carding machine. The wire comprises a plurality of first set of teeth and a plurality second set of teeth configured to be arranged alternatively to define a pattern of teeth along the length of the wire. The first set of teeth is defined by at least one first tooth and the second set of teeth is defined by at least one second tooth. The first tooth has a degree of tip flatness different from that of the second tooth.
In an embodiment, the first tooth is configured to be a sharp point tooth and wherein the second tooth is configured to be a flat-tipped tooth.
In an embodiment, the first tooth is configured to be a flat-tipped tooth having a flat tip length of L1. The second tooth is configured to be a flat-tipped tooth having a flat tip length of L2, wherein L1 is different from L2.
In an embodiment, in the pattern of teeth along the length of the wire, the number of teeth in the first set of teeth is configured to be different than the number of teeth in a preceding first set of teeth. The number of teeth in the second set of teeth is configured to be different than the number of teeth in a preceding second set of teeth.
In an embodiment, in the pattern of teeth along the length of the wire, the number of teeth in the first set of teeth is configured to be the same as the number of teeth in a preceding first set of teeth. The number of teeth in the second set of teeth is configured to be same as the number of teeth in a preceding second set of teeth B.
In an embodiment, the pitch of the first set of teeth is configured to be the same as the pitch of the preceding first set of teeth.
In an embodiment, the pitch of the second set of teeth is configured to be the same as the pitch of the preceding second set of teeth.
In an embodiment, the pitch of the first set of teeth is configured to be different from that of the pitch of the second set of teeth.
In an embodiment, the wire having the first tooth and the second tooth is made of a material selected from the group of hardened and tempered steel, high carbon steel, alloy steel, stainless steel.
In an embodiment, the pattern includes a unique pattern defined by 26 teeth and is configured to be repeated along the entire length of the wire.
In an embodiment, the pattern includes a unique pattern defined by 38 teeth and is configured to be repeated along the entire length of the wire.
In an embodiment, the wire having the first tooth and the second tooth is formed by punching operation.
In an embodiment, the pattern has a length ranging between 6 inches to 15 inches.
In an embodiment, the first tooth and the second tooth has a height ranging between 3 mm to 12 mm.
In an embodiment, the first tooth and the second tooth has a pitch ranging between 3 mm to 12 mm.
In an embodiment, the second tooth has a tip flatness that ranges between 2 mm to 6 mm.
In another aspect, the present disclosure envisages a carding roller for a carding machine. The roller comprises a cylindrical body and at least one wire configured to be wound circumferentially along the length of the cylindrical body. The wire comprises a plurality of first set of teeth and a plurality second set of teeth configured to be arranged alternatively to define a pattern of teeth along the length of the wire. The first set of teeth is defined by at least one first tooth and the second set of teeth is defined by at least one second tooth. The first tooth has a degree of tip flatness different from that of the second tooth.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A wire for a roller of a carding machine of the present disclosure, of a carding machine will now be described with the help of the accompanying drawing, in which:
Figure 1a illustrates side view of a wire of the prior art.
Figure 1b illustrates a top view of a roller with wound wire of figure 1 of the prior art.
Figure 2 illustrates an isometric view of the wire mounted on roller, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates a side view of a wire of the roller of Figure 2;
Figure 4 and Figure 5 illustrate the top view of the carding roller with carding wire wound thereon according to different embodiments of present disclosure;
Figure 6 and figure 7 illustrate the views of the wire in accordance with two different embodiments of the present disclosure;
Figure 8a illustrates the side view of two different flat-tipped teeth having different flat tip length in accordance with an embodiment of the present disclosure; and
Figure 8b illustrates the side view of the sharp point tooth and flat-tipped tooth in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
200 roller
100 wire
105 first tooth
110 second tooth
A first set of tooth
B second set of tooth
S sharp point tooth
F flat-tipped tooth
L1 flat tip length of first flat-tipped tooth
L2 flat tip length of second flat-tipped tooth
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including”, “includes” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
Figure 1a illustrates side view of a wire of the prior art and Figure 1b illustrates a top view of a roller with wound wire of figure 1 of the prior art.
Conventionally, all rollers and clearer cards within the carding machine are equipped with metallic wire 100’. This wire 100’ is wound circumferentially to ensure it cover the entire length of the roller 200’. Figure 1b shows a pattern created by the conventional wire 100’ as it is wound along the roller 200’. This pattern plays a crucial role in the processing of fibres. Figure 1b shows a uniform pattern created by sharp point teeth 105’ of the wire.
The sharp teeth 105’ of the wire 100’ create a pattern that is not ideal for handling delicate fibres. As these sharp teeth engage with the fibres during the carding process, they fail to provide the necessary gentle opening action that delicate fibres require. Instead of smoothly separating and aligning the fibres, the sharp teeth can cause damage. This damage manifests as the rupturing or breaking of the fibres thereby compromising the quality of the processed material.
Therefore, while the sharp-toothed wire 100’ is effective in certain scenarios, its conventional pattern and design are not suited for delicate fibres that need a gentler touch to maintain their integrity during the carding process. This highlights a significant limitation in the conventional design of wire-mounted rollers in carding machines, particularly when it comes to processing delicate and fine fibres without causing damage.
A preferred embodiment of a wire 100 for a roller 200 of a carding machine according to the present disclosure will now be described in detail with reference to Figure 1a through Figure 8b. The preferred embodiment does not limit the scope and embodiment of the present disclosure.
Figure 2 illustrates an isometric view of the wire mounted on roller, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates a side view of a wire of the roller of Figure 2.
A carding machine includes the roller 200 configured to be in communication with a liker-in and a doffer. The liker-in and the doffer are configured to rotate in a direction opposite to the direction of rotation of the cylinder. The machine further includes a conveyor, having a plurality of flat tops, configured to revolvingly abut the cylinder. In roller and clearer cards there are plurality of rollers named “worker” rollers in place of the flat bars. These worker rollers do the carding action.
Fibre-tufts are fed to the liker-in, from where the tufts are passed between the flat tops or worker rollers and the cylinder to facilitate preparation of fibre webs. The opened fibre webs are passed through the doffer and thereafter led to the output as slivers of fibres.
The wire 100 for the roller 200 of the carding machine comprises a plurality of first set of teeth A and a plurality second set of teeth B configured to be arranged alternatively to define a pattern of teeth along the length of the wire. Wherein, the first set of teeth A is defined by at least one first tooth 105 and the second set of teeth B is defined by at least one second tooth 106. Further, wherein the first tooth 105 has a degree of tip flatness different from that of the second tooth 106.
In an embodiment, the wire 100 having the first tooth 105 and the second tooth 110 is formed by punching a sheet of hardened and tempered steel.
In an embodiment, wherein the first tooth 105 is configured to be a sharp point tooth and the second tooth 110 is configured to be a flat-tipped tooth as shown in Figure 8b.
The sharp point tooth 105 provide an intense opening of the fibres and parallelising of fibre tufts. On the other hand, the provision of the flat-tipped tooth 110 along with sharp wire points 105 enables gentle opening of the fibres along with supporting the fibres. Although, the opening action of the flat-tipped tooth 110 is less intense as compared to the sharp point tooth 105, due to the support provided to fibre the overall chances of fibre rupture reduces.
In an embodiment, the sharp point tooth 105 and flat-tipped tooth 110 are spaced apart from other at an equal distance.
The alternative arrangement of the sharp point tooth 105 and flat-tipped tooth 110 facilitate creation of a zone of effective fibre transference. In an embodiment, the sharp point tooth 105 and flat-tipped tooth 110 are arranged in accordance with patterns as seen in Figure 4 and Figure 5.
Figure 6 and figure 7 illustrates the views of the wire in accordance with an embodiment of the present disclosure. The first tooth is configured to be a flat point tooth having a flat tip length of L1. The second tooth is configured to be a flat point tooth having a flat tip length of L2, wherein L1 is different from L2 as shown in Figure 7 and Figure 8a.
In an embodiment, wherein in the pattern of teeth along the length of the wire, the number of teeth in the first set of teeth A is configured to be different than the number of teeth in a preceding first set of teeth A. The number of teeth in the second set of teeth B is configured to be different than the number of teeth in a preceding second set of teeth B as shown in Figure 6. In another embodiment, wherein in the pattern of teeth along the length of the wire, the number of teeth in the first set of teeth A is configured to be the same as the number of teeth in a preceding first set of teeth A. The number of teeth in the second set of teeth B is configured to be same as the number of teeth in a preceding second set of teeth B.
In an embodiment, wherein the pitch of the first set of teeth A is configured to be the same as the pitch of the preceding
first set of teeth A. In an embodiment, wherein the pitch of the second set of teeth B is configured to be the same as the pitch of the preceding second set of teeth B. In another embodiment, wherein the pitch of the first set of teeth A is configured to be different from that of the pitch of the second set of teeth B.
In another aspect, the present disclosure envisages a carding roller 200 for a carding machine, the roller comprises a cylindrical body. At least one wire 100 configured to be wound circumferentially along the length of the cylindrical body. Wherein the wire 100 comprises a plurality of first set of teeth A and a plurality second set of teeth B configured to be arranged alternatively to define a pattern of teeth along the length of the wire. Further wherein, the first set of teeth A is defined by at least one first tooth 105 and the second set of teeth B is defined by at least one second tooth 106 and wherein the first tooth 105 has a degree of tip flatness different from that of the second tooth 106.
In an embodiment, The sharp point tooth 105 and flat-tipped tooth 110, are arranged in sequences that vary from one tooth to several teeth. This variation helps in randomizing the pattern of teeth on the roller 200 to prevent uniform spacing. Further when the wire is wound around the length of the roller 200 first layer of the wire forms the randomized pattern with the adjacent wire layer. This randomized pattern is repeated along the length of the roller.
The randomized pattern of wire points on the clothing roller is created through the following arrangements of the sharp point tooth 105 and flat-tipped tooth 110:
• The sharp point tooth 105 and the flat-tipped tooth 110 can be arranged in alternating sequences. For example, the sharp point tooth 105 may be followed by the flat-tipped tooth 110 and then another sharp point tooth 105 wire point, and so on.
• The plurality of sharp point tooth 105 can be followed by the plurality of flat-tipped tooth 110. For example, three sharp point tooth 105 points may be followed by two flat-tipped tooth 110. This grouping helps to further randomize the pattern as shown in Figure 6.
• The flat-tipped tooth 110 may have different shapes and sizes. By varying the shapes and sizes of the flat-tipped tooth 110, the pattern on the roller surface becomes less predictable and more random as shown in Figure 7.
In an embodiment, the randomized pattern facilitates the opening and parallelizing of fibres while reducing the rupture of delicate fibres such as wool, silk, fine synthetic fibres, dyed fibres. This randomization helps in handling fibres of variable cut lengths more effectively.
In an embodiment, wherein the wire 115 having the first tooth 105 and the second tooth 110 is made of a material selected from the group of hardened and tempered steel, high carbon steel, alloy steel, stainless steel.
In an embodiment, wherein the pattern includes a unique pattern defined by 26 teeth and is configured to be repeated along the entire length of the wire 100. This unique pattern defined by 26 teeth including plurality of first teeth 105 and plurality of second teeth 110 arranged in following order as shown in Figure 6:
• 1F, 3S, 3F, 2S, 1F, 1S, 2F, 1S, 1F, 2S, 2F, 2S, 1F, 1S, 1F, 1S, 1S
Wherein the 1S indicates one sharp point tooth 105, 2S indicates two sharp point teeth 105 and so on. Further, 1F indicates one flat-tipped tooth, 2F indicates two flat-tipped teeth and so on.
In an embodiment, wherein the pattern includes a unique pattern defined by 38 teeth and is configured to be repeated along the entire length of the wire. This unique pattern defined by 38 teeth including plurality of first teeth 105 and plurality of second teeth 110 arranged in following order as shown in Figure 7:
• 3L1, 2L2, 1L1, 1L2,2L1,2L2,1L1,1L2,2L1,1L2,1L1, 2L2,2L1,3L2, 1L1, 3L2, 1L1, 1L2, 1L1, 1L2, 2L1, 2L2,1L1,1L2
Wherein the 1L1 indicates one tooth of flat-tipped length L1, 2L1 indicates two teeth of flat-tipped length L1 and so on. Further, 1L2 indicates one tooth of flat-tipped length L2, 2L1 indicates two teeth of flat-tipped length L2 and so on.
In an embodiment, wherein the wire having the first tooth 105 and the second tooth 110 is formed by punching operation.
In an embodiment, wherein the pattern has a length that ranges between 6 inches to 15 inches.
In an embodiment, the first tooth 105 and the second tooth 110 has a height that ranges between 3 mm to 12 mm.
In an embodiment, the first tooth 105 and the second tooth 110 has a pitch that ranges between 3 mm to 12 mm.
In an embodiment, the second tooth 110 has a flat-tipped length that ranges between 2 mm to 6 mm.
Further, different unique patterns of first tooth 105 and second tooth 110 may be employed depending on various properties of fibre and degree of randomization of wire teeth required on roller.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of a wire for a roller of a carding machine:
? which efficiently transfers fibres from the roller;
? which has variable wire point patterns with areas of highly efficient fibre transference zones;
? which has reduced chances of fibre rupture;
? which increases carding effect with uniform web quality; and
? which increases productivity of the carding machine.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of materials, implants, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A wire (100) for a roller (200) of a carding machine, comprising:
• a plurality of first set of teeth (A) and a plurality second set of teeth (B) configured to be arranged alternatively to define a pattern of teeth along the length of said wire;
wherein, said first set of teeth (A) is defined by at least one first tooth (105) and said second set of teeth (B) is defined by at least one second tooth (110);
wherein said first tooth (105) has a degree of tip flatness different from that of said second tooth (110).
2. The wire (100) as claimed in claim 1, wherein said first tooth (105) is configured to be a sharp point tooth; and wherein said second tooth (110) is configured to be a flat-tipped tooth.
3. The wire (100) as claimed in claim 1, wherein said first tooth is configured to be a flat-tipped tooth having a flat tip length of L1; and said the second tooth is configured to be a flat-tipped tooth having a flat tip length of L2, wherein L1 is different from L2.
4. The wire (100) as claimed in claim 1, wherein in said pattern of teeth along the length of the wire, the number of teeth in said first set of teeth (A) is configured to be different than the number of teeth in a preceding said first set of teeth (A), and the number of teeth in said second set of teeth (B) is configured to be different than the number of teeth in a preceding said second set of teeth (B).
5. The wire (100) as claimed in claim 1, wherein in said pattern of teeth along the length of the wire, the number of teeth in said first set of teeth (A) is configured to be the same as the number of teeth in a preceding said first set of teeth (A), and the number of teeth in said second set of teeth (B) is configured to be same as the number of teeth in a preceding said second set of teeth (B).
6. The wire (100) as claimed in claim 1, wherein in said pattern of teeth along the length of the wire, the pitch of said first set of teeth (A) is configured to be the same as the pitch of preceding said first set of teeth (A).
7. The wire (100) as claimed in claim 1, wherein in said pattern of teeth along the length of the wire, the pitch of said second set of teeth (B) is configured to be the same as the pitch of preceding said second set of teeth (B).
8. The wire (100) as claimed in claim 1, wherein in said pattern of teeth along the length of the wire, the pitch of said first set of teeth (A) is configured to be different from that of the pitch of said second set of teeth (B).
9. A wire (100) as claimed in claim 1, wherein said wire (115) having said first tooth (105) and said second tooth (110) is made of a material selected from the group of hardened and tempered steel, high carbon steel, alloy steel, stainless steel.
10. A wire (100) as claimed in claim 1, wherein said pattern includes a unique sequence defined by 26 teeth and is configured to be repeated along the entire length of said wire (100), wherein said sequence of 26 teeth include plurality of said first teeth (105) and plurality of said second teeth (110).
11. The wire (100) as claimed in claim 1, wherein said pattern includes a unique sequence defined by 38 teeth and is configured to be repeated along the entire length of the wire (100), wherein said sequence of 38 teeth include plurality of said first teeth (105) and plurality of second teeth (110).
12. The wire (100) as claimed in claim 11, wherein length of said unique sequence defined by 26 teeth ranging between 6 inches to 15 inches.
13. The wire (100) as claimed in claim 12, wherein length of said unique sequence defined by 38 teeth ranging between 6 inches to 15 inches.
14. The wire (100) as claimed in claim 1, said first tooth (105) and said second tooth (110) has a height ranging between 3 mm to 12 mm.
15. The wire (100) as claimed in claim 1, said first tooth (105) and said second tooth (110) has a pitch ranging between 3 mm to 12 mm.
16. The wire (100) as claimed in claim 1, said second tooth (110) has a flat tip length ranging between 2 mm to 6 mm.
17. A carding roller (200) for a carding machine, said roller comprising:
• a cylindrical body;
• at least one wire (100) configured to be wound circumferentially along the length of said cylindrical body;
wherein said wire (100) comprising a plurality of first set of teeth (A) and a plurality second set of teeth (B) configured to be arranged alternatively to define a pattern of teeth along the length of said wire;
wherein, said first set of teeth (A) is defined by at least one first tooth (105) and said second set of teeth (B) is defined by at least one second tooth (110); and
wherein said first tooth (105) has a degree of tip flatness different from that of said second tooth (110).
Dated this 7th day of June, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI