Production equipment and preparation process for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester

Abstract

This invention discloses a production equipment and process for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester, comprising a frame, a melting element, and a drying element. A bracket is vertically fixed on the top surface of the frame. The melting element includes a screw extruder body, a heating element, and a flow guide. The screw extruder body is horizontally positioned above the frame and includes a shell that is horizontally fixed to the bracket. The heating element and the flow guide are fitted outside the shell and outside the heating element, respectively. This invention overcomes the limitations of existing methods for preparing matte masterbatch melt, which require the separate use of a dryer and a screw extruder. This not only increases the number of steps in the production of high-pore-count, ultra-dull, irregularly shaped cotton-like polyester but also increases energy consumption due to the need for heating the masterbatch in both devices.

Description

Technical Field

[0001] This invention relates to the technical field of polyester matte imitation cotton fiber production equipment, and in particular to a production equipment and preparation process for high-pore-count ultra-matte irregularly shaped imitation cotton polyester. Background Technology

[0002] In recent years, fully matte fibers have been widely used in home textiles, sports, and outdoor products due to their soft appearance, uniform matting, and superior UV protection. Fabrics made from cotton-like fibers with irregular cross-sections, high porosity, and high titanium dioxide content possess even stronger UV protection, a soft cotton feel, rapid moisture absorption, and quick-drying properties. Their breathability and dimensional stability are also superior to ordinary cotton-like fabrics. These fabrics are popular worldwide for their skin-friendly, delicate, lightweight, and crisp feel and texture. As a new textile material, the production of high-porosity, ultra-matte, irregularly shaped cotton-like polyester is characterized by long processes, high technical content, and high added value. In the current production of high-porosity, ultra-matte, irregularly shaped cotton-like polyester, the masterbatch melt needs to be prepared by first drying the masterbatch in a dryer, and then extruding and melting it in a screw extruder to form a matte masterbatch melt.

[0003] The announcement number is CN204982166U, and the name is "A Colored Polyester Filament Production Equipment". It includes a masterbatch hopper, a screw extruder, a filter, a metering pump, a dynamic mixer, and a spinning box. The screw extruder is equipped with the masterbatch hopper. The screw extruder is connected to the filter and metering pump sequentially via pipes, and then connected to a bottle flake melt pipeline. The bottle flake melt pipeline is connected to the dynamic mixer, which is connected to the spinning box via a pipeline. The dynamic mixer includes a shell and a rotor. The shell is fitted over the rotor and has an inlet and an outlet. Multiple slots are formed on the inner surface of the shell and the outer surface of the rotor, evenly distributed in a longitudinal and transverse arrangement. The slots on the inner surface of the shell and the outer surface of the rotor are staggered and opposite each other.

[0004] However, the above-mentioned process requires the color masterbatch to be dried first and then stored in the color masterbatch silo. During preparation, the color masterbatch is added from the color masterbatch silo into the screw extruder body. This results in the preparation of the masterbatch melt including two steps: a drying step and a melting step. When preparing the masterbatch melt, the masterbatch needs to be placed in a dryer for drying first, and then extruded and melted in the screw extruder body to form a matte masterbatch melt. The dryer and the screw extruder body need to be used in conjunction to prepare the masterbatch melt, which not only increases the steps in the production of high-pore-count ultra-matte irregular cotton-like polyester, but also requires both pieces of equipment to heat the masterbatch, increasing energy consumption. Summary of the Invention

[0005] The purpose of this invention is to provide a production equipment and preparation process for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester, aiming to improve the above-mentioned problems.

[0006] This invention is implemented as follows:

[0007] A production device for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester includes a frame, a melting element, and a drying element. A bracket is vertically fixed on the top surface of the frame. The melting element includes a screw extruder body, a heating element, and a flow guide. The screw extruder body is horizontally positioned above the frame and includes a shell that is horizontally fixed to the bracket. The heating element is sleeved on the outside of the shell, and the flow guide is sleeved on the outside of the heating element. The drying element includes a support plate and a drying cylinder. The support plate is vertically fixed on the top surface of the frame, and the drying cylinder is vertically fixed on the support plate. An air inlet is vertically installed at the bottom of the drying cylinder, and a material discharge element is vertically installed at the top of the drying cylinder. The two ends of the flow guide are connected to the bottom of the air inlet and the top of the drying cylinder, respectively. A discharge cylinder is fixedly connected to the bottom of the drying cylinder, and a discharge valve is installed on the discharge cylinder.

[0008] Furthermore, a feed shell is vertically connected to the side of the shell near the drying component, and a feeding motor is fixed to the end of the shell near the drying component. The feeding motor is used to drive the screw in the shell, and a masterbatch melt injection pump is fixed to the end of the shell away from the drying component.

[0009] Furthermore, the heating element includes an oil housing, which is fitted onto the outside of the housing, and both ends of the oil housing are fixed to the outer wall of the housing. Multiple heating rods are uniformly and horizontally fixed inside the oil housing, and an oil filling pipe is fixed through one end of the oil housing. A screw cap is threaded onto the end of the oil filling pipe. Multiple heat-conducting plates are uniformly and vertically arranged on the circumferential surface of the oil housing, and one end of each heat-conducting plate extends through the circumferential wall of the oil housing into the interior. The heat-conducting plates are fixedly connected to the oil housing.

[0010] Furthermore, each of the outer vertical end faces of the heat-conducting plate is provided with a convex shell in the horizontal direction, and multiple convex shells are provided on the outer vertical end face of the heat-conducting plate, and multiple convex shells are respectively fixed on the outer wall of the heat-conducting plate.

[0011] Furthermore, the air intake component includes a support ring bracket, which is installed inside the drying cylinder. Two support ring brackets are vertically installed inside the drying cylinder. A protective shell is vertically fixed to the top surface of the upper support ring bracket inside the drying cylinder, and a stirring motor is vertically fixed inside the protective shell. A guide rod cylinder is vertically rotatably connected to the upper support ring bracket inside the drying cylinder, and the bottom end of the guide rod cylinder is open. Multiple stirring rods are horizontally fixed along the vertical direction on the outer circumference of the guide rod cylinder, and multiple air outlets are opened through the multiple stirring rods. A rotating shell is vertically fixed to the lower support ring bracket inside the drying cylinder, and the bottom end of the rotating shell is connected and fixed to the duct on the exhaust ring shell. A sealing bearing is fixed in the rotating shell, and the sealing bearing is rotatably inserted into the bottom end of the guide rod cylinder.

[0012] Furthermore, the flow guide includes a heat exchange shell, which is sleeved on the outside of the oil shell, and both ends of the heat exchange shell are fixed to the outer wall of the oil shell. A heat-conducting plate extends inside the heat exchange shell. An air inlet ring shell is connected and fixed to the end of the heat exchange shell away from the dryer, and an exhaust ring shell is connected and fixed to the end of the heat exchange shell close to the dryer. A duct is connected and fixed to both the air inlet ring shell and the exhaust ring shell, and a wind pump is fixed to the duct.

[0013] Furthermore, a condenser is connected to the duct of the intake ring housing. The condenser includes a condenser shell with an opening at the bottom and an internal thread at the bottom of the inner circumferential surface. A support plate is horizontally fixed inside the condenser shell, and multiple air guide tubes are vertically and downwardly fixed on the support plate. An upper guide tube is connected to the top of the condenser shell, and the other end of the upper guide tube is fixed to the top of the drying cylinder. A lower guide tube is connected to the lower side of the condenser shell, and the other end of the lower guide tube is fixed to the end of the duct of the intake ring housing.

[0014] Furthermore, a liquid collecting shell is provided at the bottom of the condenser shell, and the liquid collecting shell is threadedly assembled with the internal thread of the condenser shell. A drain pipe is fixed through the bottom of the liquid collecting shell, and a drain valve is installed on the drain pipe of the liquid collecting shell.

[0015] Furthermore, the material discharge component includes a material discharge screen cylinder with an opening at the bottom and a vertical rod fixed inside. The material discharge screen cylinder has a spiral flow channel arranged vertically inside, and a feeding pipe is fixedly fixed vertically through the top of the material discharge screen cylinder. The feeding pipe extends upward through the drying cylinder and is fixed on the drying cylinder. A feed valve is installed on the feeding pipe, and a material discharge cone is fixed vertically at the bottom of the vertical rod.

[0016] A process for preparing high-pore-count, ultra-dull, irregularly shaped cotton-like polyester includes the following steps:

[0017] S1. Preparation of masterbatch melt: A masterbatch with a certain viscosity, melting point, and matte finish is dried and dehydrated in a production equipment for high-pore-count ultra-matte shaped imitation cotton polyester to reduce the moisture content of the masterbatch. The dried masterbatch is then extruded and melted in a screw extruder body with a set temperature and pressure to form matte masterbatch melt.

[0018] S2. Metering of mixed melt: Semi-glossy PET melt enters the dynamic mixer through the melt main pipe under a certain conveying pressure. At the same time, the masterbatch melt, which is molten by the screw extruder body, is precisely metered by the masterbatch melt injection pump and then enters the dynamic mixer together through the melt pipeline to form mixed melt. The mixed melt enters the spinning box through the pipeline.

[0019] S3. Spinning, cooling and oiling: The mixed melt in the spinning box is metered by the built-in melt metering pump and then extruded from the spinneret to form a fine melt stream. The spinneret holes are irregular cross-section spinneret holes. The fine melt stream is cooled by the ring blower to form a nascent filament. It is then oiled through the double oil nozzles to increase the oil content of the filament and increase the cohesion between the filament monofilaments.

[0020] S4. High-pore-count ultra-dull shaped polyester POY is wound and formed. After the nascent filaments are cooled and oiled, they pass through the pre-network, the first guide plate GR1, the main network, the second guide plate GR2 in sequence, and finally enter the high-speed winding head to be wound into high-pore-count ultra-dull shaped polyester POY.

[0021] S5. Production of high-pore-count ultra-dull shaped polyester DTY: High-pore-count ultra-dull shaped polyester POY and dull FDY components are twisted together on the auxiliary roller above the lower heating box of the texturing machine. The two specifications of high-pore-count ultra-dull shaped polyester POY undergo stretching and false twisting deformation through the feeding roller, upper heating box, guide, false twister, and intermediate roller. After twisting together in the auxiliary roller, it enters the lower heating box together with the FDY component to complete the stretching deformation stress relief. Finally, it enters the winding roller to be wound into high-pore-count ultra-dull shaped polyester DTY.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows: During use, the matting masterbatch is added to the drying unit for storage. When preparing the masterbatch melt, the heating element outside the screw extruder body in the melt is activated. The heating element heats the shell of the screw extruder body, generating heat to preheat the screw extruder body. This heat then activates the air pump on the inlet ring shell duct, drawing air into the heat exchange shell. The air contacts the outer wall of the oil shell and the heat-conducting plate in the heat exchange shell, carrying heat as it exits from the exhaust ring shell. The hot air is then guided from the exhaust ring shell duct into the rotating shell, and from the rotating shell into the air guide rod cylinder, finally exiting from the air outlet on the stirring cylinder rod to dry the masterbatch. The heat overflowing from the heating element is collected and guided to the drying unit using a flow guide, thus utilizing a single heat source. Simultaneously, the masterbatch in the molten section is heated to dry the masterbatch on the drying section, ensuring heat utilization and reducing energy consumption. Then, the discharge valve in the discharge cylinder at the bottom of the drying cylinder is opened, and the masterbatch falls from the drying cylinder into the preheated screw extruder body to begin preparing the masterbatch melt. This integrates the equipment for drying the masterbatch and the molten section for preparing the masterbatch melt into one unit. After drying, the masterbatch is directly added to the molten section, effectively reducing the production steps of cotton-like polyester and avoiding the step of transferring the dried masterbatch to the molten section later. The drying and melting of the masterbatch are completed in one step, reducing the production steps of cotton-like polyester. At the same time, the heat for drying the masterbatch comes from the heat dissipated by the heating element outside the screw extruder body, thus avoiding the need to set up a separate heat source for drying the masterbatch and reducing energy consumption. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0025] Figure 2 This is an exploded structural diagram of the present invention;

[0026] Figure 3 This is a schematic diagram showing the positions of the frame and the molten part in the decomposed state in an embodiment of the present invention;

[0027] Figure 4 This is a schematic diagram of the structure of the molten part in the decomposed state in an embodiment of the present invention;

[0028] Figure 5 This is a schematic diagram of the screw extruder body in a disassembled state according to an embodiment of the present invention;

[0029] Figure 6 This is a schematic diagram of the heating element in its decomposed state in an embodiment of the present invention;

[0030] Figure 7 This is a schematic diagram of the heat-conducting plate in its disassembled state in an embodiment of the present invention;

[0031] Figure 8 This is a schematic diagram of the flow guide in an exploded state in an embodiment of the present invention;

[0032] Figure 9 This is a schematic diagram of the condenser in the decomposed state in an embodiment of the present invention;

[0033] Figure 10 This is a schematic diagram of the structure of the drying component in the decomposed state in an embodiment of the present invention;

[0034] Figure 11 This is a schematic diagram of the structure of the blanking component in the disassembled state in an embodiment of the present invention;

[0035] Figure 12 This is a schematic diagram of the air intake component in a disassembled state in an embodiment of the present invention;

[0036] Figure 13 This is a flowchart of the production process of polyester matte imitation cotton fiber according to the present invention.

[0037] In the diagram: 1. Frame; 11. Bracket; 2. Molten material; 21. Screw extruder body; 211. Shell; 212. Feed shell; 213. Conveying motor; 214. Masterbatch melt injection pump; 22. Heating element; 221. Oil shell; 222. Heating rod; 223. Oil filling pipe; 224. Screw cap; 225. Heat-conducting plate; 226. Convex shell; 23. Flow guide; 231. Condenser shell; 232. Inlet ring shell; 233. Exhaust ring shell; 234. Pipe; 235. Air pump; 24. Condenser; 241. Condenser shell; 242. Support plate; 243. 244. Air guide tube; 245. Internal thread; 246. Liquid collection shell; 247. Drain valve; 248. Upper guide tube; 249. Lower guide tube; 30. Drying component; 31. Support plate; 32. Drying cylinder; 33. Feeding cylinder; 34. Air inlet component; 341. Support ring frame; 342. Stirring motor; 343. Protective shell; 344. Air guide rod cylinder; 345. Stirring cylinder rod; 346. Rotating shell; 347. Sealed bearing; 35. Material discharge component; 351. Material discharge screen cylinder; 352. Vertical rod; 353. Spiral flow channel; 354. Feeding pipe; 355. Feeding valve; 356. Material discharge cone. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to represent selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] Please see Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5As shown, a production device for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester includes a frame 1, a melting element 2, and a drying element 3. A bracket 11 is vertically fixed to the top surface of the frame 1. The melting element 2 includes a screw extruder body 21, a heating element 22, and a flow guide 23. The screw extruder body 21 is horizontally positioned above the frame 1 and includes a shell 211, which is horizontally fixed to the bracket 11. The heating element 22 is sleeved on the outside of the shell 211, and the flow guide 23 is sleeved on the outside of the heating element 22. The drying element... The drying unit 3 includes a pallet 31 and a drying cylinder 32. The pallet 31 is vertically fixed to the top surface of the frame 1, and the drying cylinder 32 is vertically fixed to the pallet 31. An air inlet 34 is vertically installed at the bottom of the drying cylinder 32, and a material discharge component 35 is vertically installed at the top of the drying cylinder 32. The two ends of the guide component 23 are respectively connected to the bottom of the air inlet 34 and the top of the drying cylinder 32. A discharge cylinder 33 is fixedly connected to the bottom of the drying cylinder 32, and a discharge valve is installed on the discharge cylinder 33. During use, matting masterbatch is added to the drying unit 3 for storage to prepare masterbatch melt. When the screw extruder body 21 is preheated, the heating element 22 outside the screw extruder body 21 in the melting section 2 is activated. The heating element 22 heats the shell 211 of the screw extruder body 21, generating heat for preheating. At the same time, the guide element 23 is activated to guide air into the guide element 23. The air then carries the heat into the drying element 3 to dry the masterbatch stored in the drying cylinder 32. After drying, the discharge valve in the discharge cylinder 33 at the bottom of the drying cylinder 32 is opened, and the masterbatch falls from the drying cylinder 32 into the preheated screw extruder body. In body 21, the masterbatch melt is prepared, thus integrating the equipment for drying the masterbatch and the melting component 2 for preparing the masterbatch melt liquid into one unit. After the masterbatch is dried, it is directly added to the melting component 2, thereby effectively reducing the production steps of cotton-like polyester and avoiding the step of transferring the dried masterbatch to the melting component 2 in the later stage. The drying and melting of the masterbatch are completed in one step, reducing the production steps of cotton-like polyester. At the same time, the heat for drying the masterbatch comes from the heat dissipated by the heating component 22 outside the screw extruder body 21, thereby avoiding the need to set up an additional heat source for drying the masterbatch and reducing energy consumption.

[0040] Please see Figure 5 The shell 211 is vertically connected to the feed shell 212 on the side near the drying component 3, and a conveying motor 213 is fixed at the end of the shell 211 near the drying component 3. The conveying motor 213 is used to drive the screw in the shell 211. The end of the shell 211 away from the drying component 3 is connected to and fixed to the masterbatch melt injection pump 214. When melting masterbatch, masterbatch is added from the feed shell 212 of the shell 211. The conveying motor 213 is started to drive the screw to rotate in the shell 211, thereby spirally pushing the masterbatch to melt in the screw extruder body 21 to prepare molten liquid. Then the molten masterbatch liquid is injected out through the masterbatch melt injection pump 214 for further processing.

[0041] Please see Figure 5 , Figure 6 and Figure 7 The heating element 22 includes an oil housing 221, which is fitted onto the outside of the housing 211. Both ends of the oil housing 221 are fixed to the outer wall of the housing 211. Multiple heating rods 222 are uniformly and horizontally fixed inside the oil housing 221. A filling pipe 223 is fixedly connected to one end of the oil housing 221, and a screw cap 224 is threaded onto the end of the filling pipe 223. Multiple heat-conducting plates 225 are uniformly and vertically arranged on the circumferential surface of the oil housing 221. One end of each heat-conducting plate 225 extends through the circumferential wall of the oil housing 221 and is fixedly connected to the oil housing 221. A convex shell 226 is horizontally arranged on the outer vertical end face of each heat-conducting plate 225. Multiple protrusions 226 are provided on the outer vertical end face of the heat-conducting plate 225, and multiple protrusions 226 are respectively fixed on the outer wall of the heat-conducting plate 225. During use, heat-conducting oil is added to the oil shell 221 through the oil filling pipe 223, and then the oil filling pipe 223 is blocked by the screw cap 224. When heating, the heating rod 222 is heated, and the heat is transferred to the heat-conducting oil. The heat-conducting oil contacts the outer wall of the shell 211, and the heat in the heat-conducting oil is transferred to the interior through the outer wall of the shell 211 for heating and melting the masterbatch. At the same time, the heat-conducting plate 225 is made of metal, and one end of the heat-conducting plate 225 contacts the heat-conducting oil, transferring heat to the other end of the heat-conducting plate 225. At the same time, the heat in the heat-conducting oil is transferred to the outer wall through the wall of the oil shell 221.

[0042] Please see Figure 1 The air inlet component 34 includes a ring support 341, which is disposed inside the drying cylinder 32. Two ring supports 341 are vertically arranged inside the drying cylinder 32. A protective shell 343 is vertically fixed to the top surface of the upper ring support 341 inside the drying cylinder 32, and a stirring motor 342 is vertically fixed inside the protective shell 343. An air guide rod cylinder 344 is vertically rotatably connected to the upper ring support 341 inside the drying cylinder 32, and the bottom end of the air guide rod cylinder 344 is open. Multiple stirring rods 345 are horizontally fixed along the vertical direction on the outer circumference of the air guide rod cylinder 344, and multiple air outlets are opened through the stirring rods 345. The lower ring support 341 inside the drying cylinder 32... A rotating shell 346 is vertically fixed at the top, and the bottom end of the rotating shell 346 is connected and fixed to the conduit 234 on the exhaust ring shell 233. A sealing bearing 347 is fixed in the rotating shell 346, and the sealing bearing 347 is rotatably inserted into the bottom end of the air guide cylinder 344. During use, the stirring motor 342 on the upper support ring frame 341 in the drying cylinder 32 is started. The stirring motor 342 drives the air guide cylinder 344 to rotate on the support ring frame 341. The masterbatch inside the drying cylinder 32 is stirred by the stirring cylinder rod 345. The hot air introduced into the air guide cylinder 344 is discharged from the air outlet on the stirring cylinder rod 345. Then the hot air evenly contacts the masterbatch at different height levels inside the drying cylinder 32, improving the effectiveness of drying the masterbatch.

[0043] Please see Figure 10 and Figure 12 The guide component 23 includes a heat exchange shell 231, which is sleeved on the outside of the oil shell 221. Both ends of the heat exchange shell 231 are fixed to the outer wall of the oil shell 221, and a heat-conducting plate 225 extends inside the heat exchange shell 231. An air inlet ring shell 232 is connected and fixed to the end of the heat exchange shell 231 away from the dryer 3, and an exhaust ring shell 233 is connected and fixed to the end of the heat exchange shell 231 near the dryer 3. A duct 234 is connected and fixed to both the air inlet ring shell 232 and the exhaust ring shell 233, and a fan pump 235 is fixed to the duct 234. During use, the fan pump 235 on the air inlet ring shell 232 and the duct 234 is started to drive air into the heat exchange shell 231. In the process, air in the heat exchange shell 231 contacts the outer wall of the oil shell 221 and the heat conduction plate 225, carrying heat and being discharged from the heat exchange shell 231 through the exhaust ring shell 233. Then, the hot air is introduced into the rotating shell 346 through the duct 234 on the exhaust ring shell 233, and then into the air guide rod cylinder 344 from the rotating shell 346. Finally, the hot air is discharged from the air outlet on the stirring cylinder rod 345 to dry the masterbatch. The overflow heat generated by the heating element 22 is collected and guided to the drying element 3 by the flow guide element 23. Thus, a single heat source is used to simultaneously heat the masterbatch in the melting element 2 and dry the masterbatch in the drying element 3, ensuring heat utilization and reducing energy consumption.

[0044] Please see Figure 8 and Figure 9A condenser 24 is connected to the conduit 234 of the intake ring housing 232. The condenser 24 includes a condenser shell 241 with an opening at the bottom. An internal thread 244 is formed on the bottom of the inner circumferential surface of the condenser shell 241. A support plate 242 is horizontally fixed inside the condenser shell 241, and multiple air guide tubes 243 are vertically and downwardly fixed on the support plate 242. An upper conduit 247 is connected to the top of the condenser shell 241, and the other end of the upper conduit 247 is fixed to the top of the drying cylinder 32. A lower conduit 248 is connected to the lower side of the condenser shell 241, and the other end of the lower conduit 248 is fixed to the end of the conduit 234 of the intake ring housing 232. A liquid collecting shell 245 is provided at the bottom of the condenser shell 241, and the liquid collecting shell 245 is threadedly assembled with the internal thread 244 of the condenser shell 241. A drain pipe is fixed to the bottom of the liquid collecting shell 245. A drain valve 246 is installed on the drain pipe of the liquid shell 245. Using the air pump 235 on the conduit 234 of the middle guide component 23, the air in the drying cylinder 32 of the drying component 3 is introduced into the condenser shell 241 through the upper conduit 247. The air introduced into the condenser shell 241 comes into contact with the air guide tube 243, and the water vapor in the air is condensed to form water droplets. The water droplets fall downward into the liquid collection shell 245. Then the condensed air is introduced into the conduit 234 of the air inlet ring shell 232 through the lower conduit 248. After passing through the air inlet ring shell 232, it is introduced into the heat exchange shell 231. In the heat exchange shell 231, the air comes into contact with the outer wall of the oil shell 221 and the heat conduction plate 225, and carries heat out of the heat exchange shell 231 through the exhaust ring shell 233. Then the hot air is introduced into the drying component 3 through the conduit 234 on the exhaust ring shell 233 to heat and dry the masterbatch, thereby recovering the heat dissipated from the melt 2 to dry the masterbatch in the drying component 3.

[0045] Please see Figure 10 and Figure 11 The material feeding component 35 includes a material feeding screen cylinder 351 with an opening at the bottom. A vertical rod 352 is vertically fixed inside the material feeding screen cylinder 351. A spiral flow channel 353 is vertically arranged inside the material feeding screen cylinder 351. A feeding pipe 354 is vertically fixed through the top of the material feeding screen cylinder 351. The feeding pipe 354 extends upwards through the drying cylinder 32 and is fixed to the drying cylinder 32. A feed valve 355 is installed on the feeding pipe 354. The bottom end of the vertical rod 352... A vertically fixed discharge cone block 356 is used. During use, the masterbatch is added from the feeding pipe 354 and then enters the discharge screen cylinder 351. After being guided by the spiral flow channel 353 inside the discharge screen cylinder 351, the masterbatch flows evenly down the spiral flow channel 353 and is then added into the drying cylinder 32. When the air flows upward, the hot air enters the discharge screen cylinder 351 and pre-dries the masterbatch flowing in the spiral flow channel 353. Because the masterbatch is dispersed by the spiral flow channel 353, the drying effect of the masterbatch is guaranteed.

[0046] A process for preparing high-pore-count, ultra-dull, irregularly shaped cotton-like polyester, characterized by the following steps:

[0047] S1. Preparation of masterbatch melt: Masterbatch with a certain viscosity, melting point and matte finish is dried and dehydrated in the production equipment of high-pore-count ultra-matte shaped imitation cotton polyester to reduce the moisture content of the masterbatch. The dried masterbatch is then extruded and melted in a specially designed screw extruder body with set temperature and pressure to form matte masterbatch melt.

[0048] S2. Metering of mixed melt: Semi-glossy PET melt enters the dynamic mixer through the melt main pipe under a certain conveying pressure. At the same time, the masterbatch melt, which is molten by the screw extruder body, is precisely metered by the masterbatch melt injection pump and then enters the dynamic mixer together through the melt pipeline to form mixed melt. The mixed melt enters the spinning box through the pipeline.

[0049] S3. Spinning, cooling and oiling: The mixed melt in the spinning box is metered by the built-in melt metering pump and then extruded from the spinneret to form a fine melt stream. The spinneret holes are irregularly shaped spinneret holes. The fine melt stream is cooled by the ring blower to form a nascent filament. It is then oiled by a specially designed double oil nozzle to increase the oil content of the filament and increase the cohesion between the filament monofilaments.

[0050] S4. High-pore-count ultra-dull shaped polyester POY is wound and formed. After the nascent filaments are cooled and oiled, they pass through the pre-network, the first guide plate GR1, the main network, the second guide plate GR2 in sequence, and finally enter the high-speed winding head to be wound into high-pore-count ultra-dull shaped polyester POY.

[0051] S5. Production of high-pore-count ultra-dull shaped polyester DTY: High-pore-count ultra-dull shaped polyester POY and dull FDY components are twisted together on the auxiliary roller above the lower heating box of the texturing machine. The two specifications of high-pore-count ultra-dull shaped polyester POY undergo stretching and false twisting deformation through the feeding roller, upper heating box, guide, false twister, and intermediate roller. After twisting together in the auxiliary roller, it enters the lower heating box together with the FDY component to complete the stretching deformation stress relief. Finally, it enters the winding puller to be wound into high-pore-count ultra-dull shaped polyester DTY.

[0052] Working principle: Masterbatch is added through feeding pipe 354 and then enters the discharge screen cylinder 351. Heat transfer oil is added to oil shell 221 through oil filling pipe 223. Then, the oil filling pipe 223 is blocked with screw cap 224. During heating, the heating rod 222 is heated, and the heat is transferred to the heat transfer oil. The heat transfer oil contacts the outer wall of shell 211, and the heat in the heat transfer oil is transferred to the interior through the outer wall of shell 211, heating the shell 211 of the screw extruder body 21. The heat generated by the preheating of the screw extruder body 21 is generated. At the same time, the guide component 23 is activated to introduce air into the guide component 23. The air pump 235 on the guide pipe 234 introduces the air in the drying cylinder 32 of the drying component 3 through the upper guide pipe 247 into the condensing shell 241. The air introduced into the condensing shell 241 contacts the air guide cylinder 243, and the water vapor in the air is condensed to form water droplets. The water droplets fall downward into the liquid collection shell 24. In step 5, the condensed air is then introduced from the lower conduit 248 into the conduit 234 of the intake ring shell 232, and then into the heat exchange shell 231 through the intake ring shell 232. In the heat exchange shell 231, the air comes into contact with the outer wall of the oil shell 221 and the heat-conducting plate 225, carrying heat and being discharged from the heat exchange shell 231 through the exhaust ring shell 233. Then, the hot air is introduced from the conduit 234 on the exhaust ring shell 233 into the drying element 3 to heat and dry the masterbatch, thereby recovering the heat dissipated from the melt element 2 to dry the masterbatch in the drying element 3. The feeding motor 213 is started to drive the screw to rotate in the shell 211, thereby spirally pushing the masterbatch to melt in the screw extruder body 21 to prepare molten liquid. Then, the molten masterbatch liquid is injected out through the masterbatch melt injection pump 214 for further processing.

[0053] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the invention by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A production equipment for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester, characterized in that, The assembly includes a frame (1), a melting element (2), and a drying element (3). A bracket (11) is vertically fixed on the top surface of the frame (1). The melting element (2) includes a screw extruder body (21), a heating element (22), and a flow guide (23). The screw extruder body (21) is horizontally positioned above the frame (1). The screw extruder body (21) includes a shell (211), which is horizontally fixed to the bracket (11). The heating element (22) is sleeved on the outside of the shell (211), and the flow guide (23) is sleeved on the outside of the heating element (22). The drying component (3) includes a tray (31) and a drying cylinder (32). The tray (31) is vertically fixed on the top surface of the frame (1). The drying cylinder (32) is vertically fixed on the tray (31). An air inlet (34) is vertically arranged at the bottom of the drying cylinder (32). A material discharge component (35) is vertically arranged at the top of the drying cylinder (32). The two ends of the guide component (23) are respectively connected to the bottom of the air inlet component (34) and the top of the drying cylinder (32). A material discharge cylinder (33) is fixedly connected to the bottom of the drying cylinder (32). A material discharge valve is installed on the material discharge cylinder (33). The housing (211) is vertically connected to the feed housing (212) on the side near the drying component (3), and a feeding motor (213) is fixed at the end of the housing (211) near the drying component (3), and the feeding motor (213) is used to drive the screw in the housing (211). The end of the housing (211) away from the drying component (3) is connected to and fixed to the masterbatch melt injection pump (214). The heating element (22) includes an oil housing (221), which is sleeved on the outside of the housing (211). Both ends of the oil housing (221) are fixed to the outer wall of the housing (211). Multiple heating rods (222) are uniformly and horizontally fixed inside the oil housing (221). A filling pipe (223) is fixed through one end of the oil housing (221). A screw cap (224) is threaded onto the end of the filling pipe (223). Multiple heat-conducting plates (225) are uniformly and vertically arranged on the circumferential surface of the oil housing (221). One end of each heat-conducting plate (225) extends through the circumferential wall of the oil housing (221) and into the interior. The multiple heat-conducting plates (225) are fixedly connected to the oil housing (221).

2. The production equipment for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester according to claim 1, characterized in that, The heat-conducting plate (225) has a convex shell (226) arranged horizontally on the outer vertical end face, and multiple convex shells (226) are arranged on the outer vertical end face of the heat-conducting plate (225), and multiple convex shells (226) are respectively fixed on the outer wall of the heat-conducting plate (225).

3. The production equipment for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester according to claim 1, characterized in that, The air inlet component (34) includes a ring support (341), which is disposed inside the drying cylinder (32). Two ring supports (341) are vertically arranged inside the drying cylinder (32). A protective shell (343) is vertically fixed to the top surface of the upper ring support (341) inside the drying cylinder (32), and a stirring motor (342) is vertically fixed inside the protective shell (343). A guide rod cylinder (344) is vertically rotatably connected to the upper ring support (341) inside the drying cylinder (32), and the bottom end of the guide rod cylinder (344) is open. The air guide cylinder (344) has multiple stirring cylinder rods (345) horizontally fixed along the vertical direction on its outer circumference. Multiple air outlets are opened through the stirring cylinder rods (345). A rotating shell (346) is vertically fixed on the lower side support ring (341) inside the drying cylinder (32). The bottom end of the rotating shell (346) is connected and fixed to the conduit (234) on the exhaust ring shell (233). A sealing bearing (347) is fixed in the rotating shell (346). The sealing bearing (347) is rotatably inserted into the bottom end of the air guide cylinder (344).

4. The production equipment for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester according to claim 3, characterized in that, The flow guide (23) includes a heat exchange shell (231), which is sleeved on the outside of the oil shell (221). Both ends of the heat exchange shell (231) are fixed on the outer wall of the oil shell (221), and a heat-conducting plate (225) extends inside the heat exchange shell (231). An air inlet ring shell (232) is connected and fixed at the end of the heat exchange shell (231) away from the dryer (3), and an exhaust ring shell (233) is connected and fixed at the end of the heat exchange shell (231) close to the dryer (3). A conduit (234) is connected and fixed on both the air inlet ring shell (232) and the exhaust ring shell (233), and a wind pump (235) is fixed on the conduit (234).

5. The production equipment for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester according to claim 4, characterized in that, A condenser (24) is connected to the conduit (234) of the intake ring shell (232). The condenser (24) includes a condenser shell (241). The bottom end of the condenser shell (241) is open, and the bottom of the inner circumferential surface of the condenser shell (241) is provided with an internal thread (244). A support plate (242) is fixed horizontally inside the condenser shell (241), and multiple air guide tubes (243) are fixed vertically downward on the support plate (242). An upper conduit (247) is connected to the top end of the condenser shell (241), and the other end of the upper conduit (247) is fixed to the top end of the drying cylinder (32). A lower conduit (248) is connected to the lower side of the condenser shell (241), and the other end of the lower conduit (248) is fixed to the end of the conduit (234) of the intake ring shell (232).

6. The production equipment for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester according to claim 5, characterized in that, The bottom end of the condenser shell (241) is provided with a liquid collection shell (245), and the liquid collection shell (245) is threadedly assembled with the internal thread (244) of the condenser shell (241). The bottom end of the liquid collection shell (245) is fixed with a drain pipe, and a drain valve (246) is installed on the drain pipe of the liquid collection shell (245).

7. The production equipment for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester according to claim 3, characterized in that, The material discharge component (35) includes a material discharge screen cylinder (351), which has an opening at the bottom end and a vertical rod (352) is vertically fixed inside the material discharge screen cylinder (351). A spiral flow channel (353) is arranged vertically inside the material discharge screen cylinder (351), and a feeding pipe (354) is vertically fixed at the top end of the material discharge screen cylinder (351). The feeding pipe (354) extends upward through the drying cylinder (32) and is fixed on the drying cylinder (32). A feed valve (355) is installed on the feeding pipe (354), and a material discharge cone block (356) is vertically fixed at the bottom end of the vertical rod (352).

8. A preparation process for high-pore-count, ultra-dull, irregularly shaped cotton-like polyester, characterized in that, The steps include the following: S1. Preparation of masterbatch melt: A masterbatch with a certain viscosity, melting point, and matte finish is dried and dehydrated in a production equipment for high-pore-count ultra-matte shaped imitation cotton polyester to reduce the moisture content of the masterbatch. The dried masterbatch is then extruded and melted in a screw extruder body with a set temperature and pressure to form matte masterbatch melt. S2. Metering of mixed melt: Semi-glossy PET melt enters the dynamic mixer through the melt main pipe under a certain conveying pressure. At the same time, the masterbatch melt, which is molten by the screw extruder body, is precisely metered by the masterbatch melt injection pump and then enters the dynamic mixer together through the melt pipeline to form mixed melt. The mixed melt enters the spinning box through the pipeline. S3. Spinning, cooling and oiling: The mixed melt in the spinning box is metered by the built-in melt metering pump and then extruded from the spinneret to form a fine melt stream. The spinneret holes are irregular cross-section spinneret holes. The fine melt stream is cooled by the ring blower to form a nascent filament. It is then oiled through the double oil nozzles to increase the oil content of the filament and increase the cohesion between the filament monofilaments. S4. High-pore-count ultra-dull shaped polyester POY is wound and formed. After the nascent filaments are cooled and oiled, they pass through the pre-network, the first guide plate GR1, the main network, the second guide plate GR2 in sequence, and finally enter the high-speed winding head to be wound into high-pore-count ultra-dull shaped polyester POY. S5. Production of high-pore-count ultra-dull shaped polyester DTY: High-pore-count ultra-dull shaped polyester POY and dull FDY components are twisted together on the auxiliary roller above the lower heating box of the texturing machine. The two specifications of high-pore-count ultra-dull shaped polyester POY undergo stretching and false twisting deformation through the feeding roller, upper heating box, guide, false twister, and intermediate roller. After twisting together in the auxiliary roller, it enters the lower heating box together with the FDY component to complete the stretching deformation stress relief. Finally, it enters the winding roller to be wound into high-pore-count ultra-dull shaped polyester DTY.

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