Review article

Textile Research Journal

2016, Vol. 86(19) 2117–2124

Improving airflow loss through the ! The Author(s) 2016

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yarn-loading slit of the air-interlacing DOI: 10.1177/0040517515621129
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nozzle using TRIZ

Makhsuda Juraeva, Dong Joo Song and Kyung Jin Ryu

Abstract
The air-interlacing nozzle has a yarn channel, an air inlet and a yarn-loading slit. The previously investigated optimum air-
interlacing nozzle was analyzed to improve the airflow loss through the slit by reducing the width of the slit and by
applying TRIZ tool. TRIZ, the theory of inventive problem solving, was applied to find a solution for the airflow loss
through the yarn-loading slit. The airflow inside the air-interlacing nozzle was computed using ANSYS CFX software. The
computational results of the air-interlacing nozzle were evaluated by the vorticity, velocity and the airflow loss. The
vorticity was increased and the airflow loss was improved slightly when the width of the slit was reduced. The yarn-
loading slit is for the yarn loading into the yarn channel before the air-interlacing process. The technical contradiction of
the air-interlacing nozzle was that reducing the width of the yarn-loading slit makes it difficult to load the yarn into the
yarn channel. Principles 10 and 31 of TRIZ were obtained through the contradiction matrix and were applied to the
nozzle. The computational results showed that the vorticity and velocity were increased and the airflow loss through
the slit was improved. The air-interlacing nozzle after applying principles of TRIZ showed better results when compared
numerically and experimentally with other existing nozzles.

Keywords
air-interlacing nozzle, TRIZ, principles of TRIZ, yarn-loading slit, vorticity

The air-interlacing process is driven by the rotating air-
flow inside the air-interlacing nozzle. The nozzle is
important in the air-interlacing process. The basic air-
interlacing nozzle consists of a yarn channel, an air inlet
and a yarn-loading slit. The air-interlacing nozzles with
different shapes of the yarn channel were investigated
experimentally and numerically.1,2 The analyses of vari-
ous yarn-channel shapes were examined by analyzing
the airflow parameters of the airflow inside the yarn
channel.3 The performance of the yarn channels of
the nozzles was investigated without the yarn-loading
slit and was evaluated by the relationship between nip
frequency and air-consumption.4,5
The objective of this research is to improve the air-
flow loss through the yarn-loading slit of the optimum
air-interlacing nozzle by reducing the width of the slit
and using TRIZ tools. TRIZ principles, which are
obtained from the contradiction matrix, were applied
to improve the airflow loss. TRIZ was presented as
creative problem solving for implementing the solutions
in various fields of engineering.6,7 The airflow inside the
air-interlacing nozzle was computed by using ANSYS
CFX software. The shape, length, width and height of
the yarn channel and the diameter of the air inlet were
the same as the optimum air-interlacing nozzle. The
nozzle was investigated by reducing the width of the
yarn-loading slit. The computational results were eval-
uated by the airflow loss through the slit, the vorticity
and velocity. The vorticity indicates the tendency of the
air to rotate and describes the yarn interlacing fre-
quency, while the airflow loss shows the amount of
air flowing out through the slit. The computational
School of Mechanical Engineering, Yeungnam University, South Korea
Corresponding author:
Professor Dong Joo Song, Yeungnam University, 214-1 Dae-dong,
Gyeongsan, Gyeonsangbuk-do 712-749, South Korea.
Email: djsong@yu.ac.kr
2118 Textile Research Journal 86(19)

results of the air-interlacing nozzle after applying The boundary conditions were imposed at the wall,
TRIZ principles were confirmed through experimental inlet, outlet and opening, as given in Table 1. The wall
results. condition was imposed on the air-interlacing nozzle
body. All the walls were treated as a no-slip velocity
condition. The inlet condition was prescribed at the air
Computational methods inlet of the nozzle. The inlet conditions were subsonic
flow with 151.98 kPa pressure and 15 C temperature.
Computational tools and turbulence model The outlet boundary condition was modeled as sub-
Computational Fluid Dynamics (CFD) technologies sonic flow with an average static pressure of 0 Pa. The
have become a vital part of design and analysis in outlet boundary condition was prescribed at both ends
both research and commercial industries. ANSYS of the yarn channel. The opening condition was used
CFX was used to analyze the airflow pattern in inside at the yarn-loading slit with an average static pressure
the air-interlacing nozzles.8 ANSYS CFX software of 0 Pa.
includes Workbench, CFX-Pre, CFX-Solver and The vorticities with different grid numbers for the
CFX-Post. The ANSYS Workbench can be used to grid validation test are given in Table 2. The vorticity
provide the geometry, or to modify the geometry pro- of airflow inside the nozzle is the curl of the velocity
vided in other data formats. ANSYS Workbench gen- and it is rotational motion of the airflow. The vorticity
erates geometry and mesh and passes the information ’~ is defined as the curl (rotational) of the flow velocity v~
required to CFX-Pre. CFX-Pre defines the flow physics,
boundary conditions, initial values and solver param-
eters, and CFX-Solver solves the problem by using the
specifications. CFX-Post provides post-processing
graphics tools to analyze and show the simulations
results. ANSYS CFX uses an implicit finite volume for-
mulation to construct the discrete equations represent-
ing the Navier–Stokes equations for the fluid flow.
CFX has turbulence models such as Shear Stress
Transport (SST), the k-! model, the k-" model, the
Baseline (BSL) k-! model, etc.9 Two-equation turbu-
lence models often fail to predict the flow separations
under adverse pressure gradient conditions. The choice
of the turbulence model depends on considerations
such as the flow physics, including massive flow separ- Figure 1. The computational domain of the air-interlacing
ations. The k-!-based SST model had similar governing nozzle.
equations to those of the standard k-! model.10

Computational domain, boundary conditions and Table 1. Boundary conditions of the nozzle
grid convergence test Boundary conditions Location Value
The nozzle of the air-interlacing process consists of the Inlet Air inlet 151.98 [kPa]
yarn channel with the yarn-loading slit and the air inlet. Outlet Yarn inlet, Yarn outlet Average 0 [Pa]
The computational domain of the air-interlacing nozzle Opening Yarn-loading slit 0 [Pa]
is shown in Figure 1. The previously investigated opti-
Wall The nozzle body Adiabatic
mum air-interlacing nozzle, which has the optimum
shape of the yarn channel, was analyzed to improve
the airflow loss through the yarn-loading slit.11 The
cross-section of the yarn channel is uniform throughout Table 2. Variation of the vorticity with the grid
the length except for the yarn inlet and the yarn outlet number
of the nozzle, while the yarn channel has divergent exits
at both ends. The air-inlet diameter was 1.3 mm, while Grid numbers, million Vorticity, 1/s
the height and the width of the yarn channel were 1.58 0.5 2.460 e+106
and 1.76 mm, respectively. The width of the yarn- 0.7 2.462 e+106
loading slit was reduced to 0.25 mm. The length of 1.0 2.466 e+106
the yarn channel and the air inlet were 15 and 5 mm,
1.5 2.4665e+106
respectively.
Juraeva et al.
vector. The definition can be expressed by the vector
analysis as
 
@ @ @
yarn-loading slit with the yarn channel and the air inlet
’~ ¼ r  v~ ¼ , ,  vx , vy , vz
@x @y @z
 
@vz @vy @vx @vz @vy @vx
¼  ,  , 
@y @z @z @x @x @y
where r is the del operator. The vorticity is related to
the circulation of flow (line integral of the velocity)
along a closed path by the Navier–Stokes equation.12
A grid convergence study was performed and the con-
vergence occurred after around 18 h on a PC depending
on the grid number typically. Grid convergence test
results indicated that the proper number of elements
for the computations and the grid numbers was
approximately 1,000,000. The vorticity was almost the
same when the grid numbers were 1,500,000. The grid
numbers had no significant effect on the computational
results; therefore, 1,000,000 was used for the computa-
tions. The minimum and the maximum grid sizes were
based on the converged solutions.
Implementation of TRIZ methodology
TRIZ was introduced by Russian scientist Genrich S
Altshuler (1926–1998) and it meant the theory of
inventive problem solving, based on analyzing and
researching more than 250,000 patents all over the
world.13 TRIZ is based on two basic principles. The
first principle is somebody, sometime, somewhere has
already solved your problem or one similar to it.
Creativity means finding that solution and adapting it
to the current problem. The second principle is do not
accept contradictions but resolve them. TRIZ was used
in the manufacturing and material processing indus-
tries. Integration of TRIZ concepts with creative prob-
lem solving proves to be effective for implementing the
solutions in various fields of engineering.
Definition and analysis of the problem. Figure 2 shows the
process of the problem solving that was used in this
study.14 Defining and analyzing the nature of a prob-
lem is the most important part of solving the undesir-
able effect of the air-interlacing process when using the
air-interlacing nozzle, that is, some portion of the air-
flow from the air inlet flows out through the
Figure 2. Appling process of the TRIZ methodology for this problem.
2119
yarn-loading slit. The task of the research was finding
methods to improve the airflow loss. The root cause of
the airflow leakage was that the connecting area of the
was open.
The function of the air-interlacing nozzle is to open
the yarn set using air-jet flow. The purpose of the study
was to reduce the airflow loss through the yarn-loading
slit. The technical contradiction was that reducing the
width of the yarn-loading slit makes it difficult to load
the yarn into the yarn channel.
Solutions through applying the principles of TRIZ and
implementations. The contradiction matrix, frequently
used in the TRIZ method, suggests inventive principles
to solve technical contradictions arising while trying to
improve a feature or a characteristic of any product,
process or system. There are improving and worsening
features in the first column and row of the contradic-
tion matrix. The matrix was developed by G Altshuller,
and it consolidates known system contradictions and 40
inventive principles. The contradiction matrix presents
some inventive principles to solve the contradiction
arising while trying to improve the airflow loss through
the slit. There were four suggested principles for this
problem from the contradiction matrix. They were
principles 10, 18, 39 and 31 of TRIZ. Principle 10 of
TRIZ is preliminary action – ‘‘perform, before it is
needed, the required change of an object.’’ Principles
18 and 39 are mechanical vibration and inert atmos-
phere, respectively. Principle 31 of TRIZ is porous
material – ‘‘make an object porous or add porous elem-
ents.’’ Principles 10 and 31 of TRIZ were chosen for the
implementation. Applying principle 31 of TRIZ was to
close the connecting area with porous material. The
porosity of the solid material is close to zero.
Principle 10 was applied to close the area before the
air-interlacing process starts.
Results and discussion
The airflow loss through the yarn-loading slit
of the air-interlacing nozzle with the heart- shaped
yarn channel
Air-interlacing is a physical process using air without
chemical additives and is used to process synthetic yarn
2120
in the textile industry. The air-interlacing process is
mainly contributed by the vortex motion of the airflow
inside the air-interlacing nozzle. The air-interlacing
nozzle is important in the air-interlacing process. The
air-interlacing nozzle with the optimum shaped yarn
channel was analyzed by the steady, turbulent, com-
pressible Navier–Stokes solver. The nozzle shows
better results when compared with the existing indus-
trial nozzle. The air-interlacing nozzle was investigated
to improve the airflow loss through the yarn-loading
slit by reducing the width of the slit. The height and
the width of the yarn channel were 1.58 and 1.76 mm,
respectively, while the length was 15 mm. The air-inlet
diameter was 1.3 mm, while the length was 5 mm. The
computations were performed with inlet pressure con-
ditions at 151 kPa.
The vorticity and velocity distributions at the center
of the air-interlacing nozzle are shown in Figure 3.
The airflow vortices were formed at the top part of
the yarn channel. The vorticity was strong at the
center of the yarn channel and decreased gradually
towards the channel exits (yarn outlet and yarn
inlet). The velocity was high at the center part of
the yarn channel. The compressed air from the air
inlet impinges upon the opposing wall of the yarn
channel, divides into two branches as the airflow
rotates and the compressed-air flows out through
both ends of the yarn channel.9 The compressed air-
jet opens the yarn set. The yarn motion was strongly
influenced by the strength of the compressed-air force
in the yarn channel.
Figure 4 shows the connected part of the yarn-load-
ing slit with the air inlet and the yarn channel, and the
velocity and vorticity distributions at the connected
part. The velocity of the air-jet flowing through the
connected part was 324.9 m/s. The maximum vorticity
Figure 3. The vorticity and velocity distributions at the center of the air-interlacing nozzle (cross-sectional view).
Textile Research Journal 86(19)
around the connected part was 3.597106 1/s. Some
part of the airflow from the air inlet flowed out through
the connected part of the air inlet and the yarn-loading
slit. There were two airflow losses, one at the connected
part of the yarn-loading slit with the air inlet and the
other airflow loss at the connected area of the slit with
the yarn channel. The airflow loss at the connected part
of the slit with the air inlet was significant. The airflow
loss through the slit was calculated through the airflow
that enters through the air inlet. The airflow loss in the
nozzle with the reduced slit was about 14%, while the
airflow loss was about 16% at the connected part of
the optimum air-interlacing nozzle. However, the air-
interlacing nozzle needs other methods to improve the
airflow loss through the connected part of the air inlet
and the yarn-loading slit.
Applying the principles of TRIZ
Principles 10 and 31 of TRIZ, which are suggested from
the contradiction matrix, were applied for the air-inter-
lacing nozzle to improve the airflow loss through the
yarn-loading slit. TRIZ principle 31 was applied as the
closing connected area with solid material. The compu-
tational domain was computed when the connected
part was completely closed. The yarn-loading slit
needs to load the yarn into the yarn channel and
during the air-interlacing process the slit can be
closed. The applying principle 10 of TRIZ was to
close the connecting area before the air-interlacing pro-
cess starts. Figure 5 shows the velocity and vorticity
distributions at the center of the nozzle when the con-
nected part has a closing/opening valve. The vorticity
was slightly increased while the velocity was increased
at the center of the yarn channel. The airflow loss
through the connected area was improved.
Juraeva et al. 2121

Figure 4. The velocity and vorticity distributions at the connected part: (a) the velocity distributions at the connected part of the air
inlet and the yarn-loading slit (top view); (b) the vorticity distributions at the connected part of the air inlet and the yarn-loading slit
(top view); (c) the connected part of the air inlet and the yarn-loading slit (transparent view).
2122 Textile Research Journal 86(19)

Figure 5. The velocity and vorticity distributions: (a) the vorticity and velocity distributions at the center of the nozzle when the
connected part is closed (cross-sectional view); (b) the connected part of the air inlet and the yarn channel with the yarn-loading slit is
closed (transparent view).

Table 3. The maximum vorticity and the airflow loss through the yarn-loading slit for all nozzles

Optimum nozzle Optimum nozzle

CTPZ Optimum nozzle (reduced slit) (closing/opening valve)

Vorticity, 1/s 2.204106 3.331106 3.843106 3.895106

Airflow loss, % 20 16 14 0

loss through the yarn-loading slit. The compared noz-

Validations of the computational results
The computational results of the nozzle after applying
the TRIZ principle were compared with existing noz-
zles, which were the CTPZ industrial nozzle, the nozzle
that has the optimum shape of the yarn channel and the
nozzle with a reduced slit. Table 3 presents the max-
imum vorticity inside the yarn channel and the airflow
zles were similar in shape and dimensions, such as
cross-sectional areas for the yarn channel. The diameter
of the air inlet of all nozzles was 1.3 mm. The width and
the height of the yarn channel for the CTPZ nozzle
were 1.7 and 1.6 mm, respectively, while the width
and the height of the yarn channel of the optimum
nozzle were 1.76 and 1.58 mm, respectively.15
Juraeva et al.
Table 4. Experimental results of the nozzles
Optimum
Optimum nozzle (closing/
CTPZ nozzle opening valve)
Air pressure, kgf/cm2 2.5 2.5 2.5
Twisting number, knots/m 22.5 24.5 24.8
CV% (coefficient of variation) 3.4 3.2 3.1
The width of the yarn-loading slit of the optimum
nozzle was decreased to 0.25 mm. The computations
were held under the same boundary and solver
conditions.
The computational results of the nozzles showed
that the nozzle with a closing/opening valve provides
better performance compared to the other existing noz-
zles. The maximum vorticity was increased, while the
airflow loss through the yarn-loading slit was improved
when the TRIZ principles were applied. The computa-
tional results suggest that closing the connected part
fully or partly improves the airflow loss.
Validations of the experimental results
The air-interlacing nozzle that has the TRIZ application
was compared experimentally with the optimum nozzle
and CTPZ industrial nozzle. The nozzle was fabricated
as a prototype to compare with the existing nozzles. The
air inlets of the nozzles were the same, while the shapes
of the yarn channel were similar. Experiments were held
under the same test conditions for the nozzles. The yarn
used in this test is 100% polyamide, FDY dtex50f36.
The tests of all nozzles were conducted by a high-speed
winder for the production of air-interlacing yarns. The
experimental results of the air-interlacing nozzles
showed that the nozzle with a closing/opening valve
provided better performance compared to the optimum
nozzle and the industrial nozzle, as shown in Table 4.
Checking the number of the knots was done visually in a
water bath. The nozzle yielded more interlacing knots
with low air-consumption for the given air-interlacing
process. The coefficient of variation of the yarn was
slightly improved. The nozzle with a closing/
opening valve had high velocity and maximum vorticity
strength with a lower energy consumption for process-
ing of the synthetic yarns.
Conclusions
The previously investigated the optimum air-interlacing
nozzle was analyzed using TRIZ tools to improve the
airflow loss through the yarn-loading slit. TRIZ tools
present creative solutions and new insight to solve
2123
engineering problems. The airflow inside the nozzle of
the air-interlacing process was analyzed by the steady,
turbulent, compressible Navier–Stokes solver of
ANSYS CFX. The objective of the research was to
reduce the airflow loss through the yarn-loading slit
of the optimum air-interlacing nozzle. The computa-
tional results of the nozzle were evaluated by the vor-
ticity, velocity and airflow loss.
The computational results of the optimum nozzle
and the nozzle with the reduced slit were compared
under the same boundary and solver conditions. The
nozzles consist of a yarn channel, an air inlet and yarn-
loading slit. The shape of the yarn channel was nearly
heart-shaped, while the width and the height of the yarn
channel were fixed as 1.76 and 1.58 mm, respectively.
The diameter and the length of the air inlet were 1.3 and
5 mm, respectively. The width of the yarn-loading slit
was reduced to 0.25 mm. The vorticity was slightly
increased and the airflow loss was decreased when the
width of the slit was reduced. Principles 10 and 31 of
TRIZ, which are suggested from the contradiction
matrix, were used to improve the airflow loss through
the yarn-loading slit. TRIZ principle 31 was applied to
install porous material at the connected area and prin-
ciple 10 of TRIZ was applying principle 31 of TRIZ
before the air-interlacing process starts. The yarn-
loading slit was investigated when the slit was closed
completely. The vorticity and the velocity were
increased at the center of the yarn channel. The com-
putational results of the air-interlacing nozzle after
applying the principles of TRIZ were compared with
the existing nozzles, which are similar in shape and
dimensions. The results of the nozzles show that the
air-interlacing nozzle with a closing/opening valve pre-
sented better performance compared to the existing
nozzles. The vorticity was increased and the airflow
loss through the yarn-loading slit was improved.
The computational results suggest that closing the
connected area of the slit with the air inlet and the
yarn-loading improves the airflow loss during the air-
interlacing process. The air-interlacing nozzle with a
closing/opening valve is compared experimentally
with the existing nozzles under similar operating condi-
tions. The comparisons show that the nozzle has better
performance than the existing industrial nozzle.
Declaration of conflicting interests
The authors declared no potential conflicts of interest with
respect to the research, authorship and/or publication of this
article.
Funding
The authors disclosed receipt of the following financial sup-
port for the research, authorship, and/or publication of this
2124
article: This research was supported by Yeungnam University
research grants in 2014.
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