The first problem I faced was the shapes of channels. Most existing interlacing nozzles have channels that are circular, triangular, square, semicircle, or elliptical, and all of them are patent protected. I wondered if there was any other shape of channel which could make higher entanglement efficiency. It was very difficult for me to understand the relations between Air Turbulence efficiency and channel shape. So, I tried several shapes of channels, repeated many tests, and recorded the results of the tests. Finally I found that the Scalene Hexagon is, as a result, a world innovative design.
At the same time, I needed to think about the design of Air Injections, because High efficiency of air turbulence could be realized when I could design both successful channels and air injections. I designed the Nozzle with two air injectors from which air would come straight down to Scalene Hexagon Channel. I succeeded in designing the Interlacing Nozzle that produces high quality yarns with high degrees of entanglement and consumes less air than other interlacing nozzles.
During repeating trials, I found the very important thing. That was depending on the location of support guides on machine, yarn could not be set in the center of channel correctly. This was a big problem which would harm the good features of Scalene Hexagon Channel and Multi-Air Injections. So, I started to design the yarn guides which would lead the yarn in the right center of the channel by setting it from any directions at any times. I made many trials changing the size of channel, making channel tapered, changing the locations of yarn guides, but all of them were not satisfactory. When looking at yarn guides, just like by an accident, one idea came onto my mind. That was to intentionally put two yarn guides on each end eccentric.
This Double Yarn Guides could lead the yarn in the right center of the channel regardless of the location of support guides from any directions, which helped our customers to set the yarn in the channel very easily without worrying about the location or direction of yarn from support guides.
For the development of Interlacing Nozzle, one of our customers helped me to make trial runs at his factory. One day, he told me that it was very convenient and useful if he could diassemble nozzles at one second each time when he needed to exchange nozzles for cleaning. Existing interlacing nozzles screw up nozzles with one or two bolt screws. For cleaning nozzles, it was so troublesome and took much time to diassemble nozzles from holders, screwing down the bolts with a screw driver. Our trial interlacing nozzle also needed to be assembled with two bolt screws, I changed this design to use only one screw bolt which can be screwed up and down by hand not using any screw driver. This new designed Quick Assembly Holder not only saves time for diassembling but also makes machine keep running longer hours to increase the productivity. I learned that the most important thing to develop any new products was to listen to the customers, and try to meet any small requests or needs of customers.
