One-step terylene manufacturing system and method thereof

Abstract

The application provides a one-step polyester manufacturing system and method thereof, and belongs to the technical field of polyester manufacturing, and comprises: a batching unit; a vacuum screw extrusion unit, which comprises a screw extruder and a vacuum exhaust mechanism, the screw extruder comprises a cylinder, a screw and a head, the screw is coaxially arranged in the inner cavity of the cylinder, the feeding port of the head is in communication with the discharging port of the cylinder, the vacuum exhaust mechanism is arranged in communication with the cylinder, and the discharging port of the batching unit is in communication with the feeding port of the cylinder; and a drawing unit, which is connected with the discharging end of the head and is used for receiving the filaments extruded by the vacuum screw extrusion unit and performing drawing and oil immersion treatment to obtain polyester fibers. The application greatly improves the polyester production efficiency, the whole production system is fully automatic, a large amount of labor cost is saved, and the land area is saved.

Description

Technical Field

[0001] This invention relates to the field of polyester manufacturing technology, and specifically to a one-step polyester manufacturing system and method. Background Technology

[0002] The main raw materials of polyester are terephthalic acid and ethylene glycol. After being mixed in a certain proportion, they undergo an esterification reaction to produce diethyl terephthalate, which then undergoes a polycondensation reaction to produce ethylene glycol terephthalate (PET). The PET is heated and melted, and then spun out through a spinneret to form fine filaments. After cooling, stretching, winding and other processes, polyester fibers are produced.

[0003] In the production of polyester, PET synthesis requires an esterification reaction. Polyester raw materials, especially waste polyester raw materials, contain a large amount of moisture, which can interfere with the esterification reaction balance, reducing the polymer's molecular weight and degree of polymerization. Furthermore, the moisture in the polyester raw materials may cause hydrolysis of the polymer, affecting the fiber's strength and properties. Additionally, during spinning, the moisture in the raw materials may lead to unstable melt viscosity, affecting spinning uniformity and fiber quality. Therefore, the moisture content of polyester raw materials usually needs to be strictly controlled below 0.01% to ensure the smooth progress of the polymerization reaction, fiber quality, and processing stability. Currently, a vacuum drum machine is commonly used to dry the polyester raw materials for more than 12 hours. After drying, the polyester raw materials are manually unloaded from the vacuum drum machine and transferred to a screw extruder, where they are extruded through a spinneret to form fine filaments.

[0004] After polyester fibers are formed into filaments through a spinneret, they have a high coefficient of friction, making them prone to static electricity and resulting in insufficient spinnability. To improve the processing performance of polyester fibers and the quality of the final product, an oiling process is usually included. Operators wind the filaments ejected from the spinneret and collect them in a filament container. Oil is then added to the container, and the filaments are soaked for at least 6 hours.

[0005] It is evident that the drying and oiling processes in polyester processing are intermittent, time-consuming, and severely impact polyester production efficiency. Furthermore, these processes require a significant amount of manual labor. The drying process involves high working temperatures and high dust content in the air, creating a harsh working environment that seriously affects the physical and mental health of operators. Additionally, equipment such as vacuum drum machines and yarn collection drums occupy a large area. Summary of the Invention

[0006] In view of the technical problems existing in the background art, this application provides a one-step polyester manufacturing system and method, which aims to solve the technical problems of low intermittent production efficiency, large amount of labor consumption and large equipment footprint of existing polyester manufacturing methods.

[0007] In a first aspect, embodiments of this application provide a one-step polyester manufacturing system, comprising:

[0008] Ingredient preparation unit;

[0009] A vacuum screw extrusion unit includes a screw extruder and a vacuum exhaust mechanism. The screw extruder includes a barrel, a screw, and a die head. The screw is coaxially arranged in the inner cavity of the barrel. The feed inlet of the die head is connected to the discharge outlet of the barrel. The vacuum exhaust mechanism is connected to the barrel. The discharge outlet of the batching unit is connected to the feed inlet of the barrel.

[0010] The drawing unit is connected to the discharge end of the die head. It is used to receive the filaments extruded by the vacuum screw extrusion unit and to draw and oil-immerse them to produce polyester fibers.

[0011] In some embodiments, the barrel includes a feeding section, a compression section, a vacuum section and a metering section arranged sequentially along the raw material conveying direction. An exhaust hole is provided on the inner wall of the vacuum section of the barrel. A vacuum exhaust mechanism is fixedly connected to the barrel and communicates with the inner cavity of the barrel through the exhaust hole.

[0012] The vacuum exhaust mechanism is a water jet vacuum pump, and the vacuum degree of the vacuum section controlled by the vacuum exhaust mechanism is <0.09Mpa.

[0013] In some embodiments, a first heating component is provided outside the barrel. The first heating component controls the temperature of the feeding section to be 230-250°C, the temperature of the compression section to be 260-280°C, the temperature of the vacuum section to be 260-270°C, and the temperature of the metering section to be 270-280°C.

[0014] In some embodiments, the drawing unit includes a first drawing machine, an oil bath drawing furnace, a second drawing machine, a steam drawing furnace, and a third drawing machine arranged sequentially along the material conveying direction;

[0015] The first drawing machine receives the filaments extruded from the discharge end of the die head and transports the filaments to the oil bath drawing furnace for drawing and oil immersion treatment.

[0016] The second drawing machine receives the filaments from the oil bath drawing furnace and transports them to the steam drawing furnace for drawing.

[0017] The third drawing machine receives the fine filaments from the steam drawing furnace to obtain polyester fibers.

[0018] In some embodiments, the oil bath drawing furnace includes an oil bath tank, a plurality of conveying rollers, and a second heating assembly. The oil bath tank is provided with an oil agent, and the conveying rollers are disposed in the oil bath tank. The filaments are wound around the conveying rollers so that the filaments are immersed in the oil agent.

[0019] The oil bath is divided into a first oil bath and a second oil bath. The second heating element is located outside the oil bath and is used to keep the temperature inside the first oil bath at 90-100℃ and the temperature inside the second oil bath at 150-160℃.

[0020] In some embodiments, the first oil bath contains a first oiling agent, which, by mass parts, includes 70-80 parts paraffin oil, 20-30 parts penetrant, 10-15 parts polyethylene glycol, 3-5 parts KH550, 2-3 parts lubricant, and 7-9 parts antistatic agent; the polyethylene glycol has a molecular weight of 400-600.

[0021] The second oil bath contains a second oiling agent, which, by mass fraction, includes 70-80 parts paraffin oil, 20-30 parts penetrant, 3-5 parts nano-SiO2, 2-3 parts dispersant, 2-3 parts lubricant, and 7-9 parts antistatic agent.

[0022] In some embodiments, multiple spinnerets are arranged side by side at the discharge end of the die head, and the raw material melt in the barrel is transported to the spinnerets by the screw and extruded to form fine filaments;

[0023] Each spinneret has several spinneret holes with a diameter of 0.1 to 0.7 mm.

[0024] In some embodiments, the one-step polyester manufacturing system further includes a post-processing unit, which includes a yarn stacking machine, a crimping machine, a heat setting oven, a cutting machine, and a packaging machine arranged sequentially along the material conveying direction, for sequentially performing yarn stacking, crimping, setting, cutting, and packaging processes on the polyester fibers exported from the drawing unit.

[0025] Secondly, embodiments of this application provide a one-step polyester manufacturing method, comprising the following steps:

[0026] The batching unit mixes the raw materials in proportion to obtain a mixture;

[0027] The mixture is heated and melted into a first melt using a screw extruder. A vacuum exhaust mechanism removes moisture and volatile gases from the first melt to obtain a second melt, the moisture content of which is less than 0.01%.

[0028] The second melt is extruded through a screw extruder to form fine filaments;

[0029] The filaments are drawn and oil-immersed in a drawing unit to obtain polyester fibers. The oil immersion process includes a first oil immersion and a second oil immersion. The first oil immersion temperature is 90-100℃ and the oil immersion time is 5-10s. The second oil immersion temperature is 150-160℃ and the oil immersion time is 10-20s.

[0030] In some embodiments, the raw materials, by mass fraction, include 40-50 parts of waste polyester bottle flakes, 30-45 parts of waste polyester textile foam, 0.2-0.5 parts of composite antioxidant, 0.3-0.8 parts of fatty acid ester lubricant, 0.5-0.8 parts of nano calcium oxide, and 3-5 parts of color masterbatch.

[0031] The advantages of this application, which differ from existing technical solutions, include:

[0032] 1. In the polyester manufacturing system of this invention, a vacuum screw extrusion unit replaces the original vacuum drum extruder and screw extruder. The screw extruder is equipped with a vacuum exhaust mechanism. After the polyester raw material enters the screw extruder, under the condition that the vacuum degree in the vacuum exhaust section is <0.09Mpa, the moisture in the raw material can be discharged in 5 to 7 minutes, reducing the moisture content in the raw material to below 0.01%, which meets the standard for polyester spinning. Moreover, the temperature of the raw material in the vacuum exhaust section is 260 to 270°C, which is in a molten state. The volatile gases in the raw material volatilize at high temperature and can also be discharged with the moisture, which greatly reduces the VOC content in the finished polyester and improves the quality of the polyester product, making it suitable for manufacturing automotive interior trim.

[0033] 2. This invention uses an oil bath drawing furnace instead of a wire container. The filaments are immersed in oil in the oil bath drawing furnace. By using high temperature and high concentration of oil in the oil bath drawing furnace, the oil can combine with the filaments in a short time, which greatly shortens the oil immersion time. This invention employs a two-stage oil immersion process. The first immersion temperature is relatively low, and a penetrant, polyethylene glycol, and surfactant are added to the oil. Under the action of the penetrant, polyethylene glycol embeds between polyester molecular chains, weakening the intermolecular forces and enhancing the mobility of molecular chain segments. This relaxes the stress on the polyester surface, resulting in more uniform polyester yarn and a smoother surface under stretching, reducing the impact of recycled polyester on the surface roughness of the polyester fibers. The second immersion temperature is higher, and a nano-SiO2 nucleating agent and dispersant are added to the oil. The dispersant facilitates the uniform dispersion of nano-SiO2 in the oil. During the first immersion process, the polyester fiber surface is coated with KH550, which facilitates the adsorption of nano-SiO2 on the polyester fiber surface, increasing the crystallinity of the polyester fiber surface, thereby improving the smoothness and strength of the polyester fiber.

[0034] 3. This invention improves the existing polyester spinning process by designing a vacuum screw extrusion unit and an oil bath drawing furnace, realizing one-step continuous polyester production. The polyester production process eliminates the need for transfer and prolonged oil immersion, reducing the polyester production time from approximately 2 days to 30 minutes, significantly improving polyester production efficiency. The entire production system is fully automated, saving a significant amount of labor costs. At the same time, it eliminates the need for a large vacuum drum machine and a large amount of space required for transferring yarn, saving land area.

[0035] The above description is merely an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, specific embodiments of this application are given below. Attached Figure Description

[0036] To more clearly illustrate the technical solution of this application, the accompanying drawings used in this application will be briefly described below. Obviously, the drawings described below are merely some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without any creative effort.

[0037] Figure 1 This is a schematic diagram of the structure of an embodiment of this application.

[0038] Figure Descriptions: 1. Batching Unit; 11. Hopper; 12. Feeder; 2. Vacuum Screw Extrusion Unit; 21. Screw Extruder; 211. Barrel; 212. Screw; 213. Drive Motor; 214. Die Head; 215. First Heating Component; 22. Vacuum Exhaust Mechanism; 23. Exhaust Hole; 24. Spinneret; 3. Drawing Unit; 31. First Drawing Machine; 32. Oil Bath Drawing Furnace; 321 321a, First oil bath; 321b, Second oil bath; 322, Conveyor roller; 323, Second heating assembly; 33, Second drawing machine; 34, Steam drawing furnace; 35, Third drawing machine; 4, Feeding roller; 5, Front upper oil roller; 6, Post-processing unit; 61, Thread stacking machine; 62, Rear upper oil roller; 63, Curling machine; 64, Heat setting oven; 65, Cutting machine; 66, Packing machine. Detailed Implementation

[0039] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0041] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0042] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0043] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character "" in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0044] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0045] Existing polyester production methods include the following steps:

[0046] Step 1: Raw materials → Vacuum drum extruder → Screw extruder → Metering pump → Spinneret → Oiling → Winding → filament collection hopper;

[0047] Step 2: Wire container → Bundling → Primary drawing → Water bath drawing → Secondary drawing → Steam drawing → Tertiary drawing → Wire stacking machine → Steam preheating → Curling → Oiling → Heat setting → Tension adjustment → Cutting machine → Packing machine → Weighing → Hydraulic hoist bagging truck → Warehousing.

[0048] The vacuum drum drying process takes about 12 hours. After drying, the raw materials need to be transferred to the screw extruder. The filaments ejected from the spinneret need to be collected in a filament container, soaked in oil for more than 6 hours, and then fed into the primary drawing machine through a bundling device. This results in multiple transfers in the polyester production process, taking about 2 days from material input to output. The production efficiency is low, it requires a lot of manpower, and the vacuum drum and filament container occupy a large area.

[0049] To address the technical problems of low efficiency, high labor costs, and large equipment footprint in existing polyester manufacturing methods, this application provides a one-step polyester manufacturing system and method. By designing a vacuum screw extrusion unit and an oil bath drawing furnace, the existing polyester spinning process is improved, enabling continuous one-step polyester production. The polyester production process eliminates the need for transfer and prolonged oil immersion, reducing the production time from approximately 2 days to 30 minutes, significantly improving production efficiency. The entire production system is fully automated, saving substantial labor costs. Furthermore, it eliminates the need for a large vacuum drum and the space required for transporting yarn, thus saving land area.

[0050] Firstly, such as Figure 1 As shown, this application provides a one-step polyester manufacturing system, including:

[0051] Ingredient preparation unit 1;

[0052] The vacuum screw extrusion unit 2 includes a screw extruder 21 and a vacuum exhaust mechanism 22. The screw extruder 21 includes a barrel 211, a screw 212 and a die head 214. The screw 212 is coaxially arranged in the inner cavity of the barrel 211. The feed port of the die head 214 is connected to the discharge port of the barrel 211. The vacuum exhaust mechanism 22 is connected to the barrel 211. The discharge port of the batching unit 1 is connected to the feed port of the barrel 211.

[0053] The drawing unit 3 is connected to the discharge end of the die head 214. It is used to receive the filaments extruded by the vacuum screw extrusion unit 2 and to draw and oil-immerse them to produce polyester fibers.

[0054] In some embodiments, the barrel 211 includes a feeding section, a compression section, a vacuum section and a metering section arranged sequentially along the raw material conveying direction. An exhaust hole 23 is provided on the inner wall of the vacuum section of the barrel 211. The vacuum exhaust mechanism 22 is fixedly connected to the barrel 211 and communicates with the inner cavity of the barrel 211 through the exhaust hole 23.

[0055] The vacuum exhaust mechanism 22 is a water jet vacuum pump, and the vacuum exhaust mechanism 22 controls the vacuum degree of the vacuum section to be <0.09Mpa.

[0056] In some embodiments, a first heating component 215 is provided outside the barrel 211. The first heating component 215 controls the temperature of the feeding section to be 230-250°C, the temperature of the compression section to be 260-280°C, the temperature of the vacuum section to be 260-270°C, and the temperature of the metering section to be 270-280°C.

[0057] In the technical solution of this application embodiment, the polyester raw material enters the screw extruder 21 from the batching unit 1 and then enters the feeding section. The screw 212 rotates and pushes it forward in the screw channel. It is initially softened at the preheating temperature of 230-250°C in the feeding section. Then it enters the high-temperature compression section of 260-280°C. Under the combined action of shearing by the screw 212 and heating by the barrel 211, it is completely melted and plasticized to become a uniform first melt. Subsequently, the first melt enters the vacuum section, where moisture and low-molecular-weight volatiles are extracted by the vacuum exhaust mechanism 22, reducing the moisture content to below 0.01% to form a second melt. Finally, the second melt is filtered for impurities by the filter screen of the die head 214 and evenly distributed by the distribution plate before being extruded from the spinneret holes on the spinneret plate 24.

[0058] This application replaces the original vacuum drum extruder and screw extruder 21 with a vacuum screw extruder unit 2. The screw extruder 21 is equipped with a vacuum exhaust mechanism 22. After the polyester raw material enters the vacuum screw extruder 21, under the condition that the vacuum degree in the vacuum exhaust section is <0.09Mpa, the moisture in the raw material can be discharged in 2-3 seconds, reducing the moisture content in the raw material to below 0.01%, which meets the standard for polyester spinning. Moreover, the temperature of the raw material in the vacuum exhaust section is 260-280℃, which is in a molten state. The volatile gases in the raw material volatilize at high temperature and can also be discharged with the moisture, which greatly reduces the VOC content in the finished polyester and improves the quality of the polyester product, which can be used to make automotive interior trim.

[0059] In some embodiments, the drawing unit 3 includes a first drawing machine 31, an oil bath drawing furnace 32, a second drawing machine 33, a steam drawing furnace 34 and a third drawing machine 35 arranged sequentially along the material conveying direction;

[0060] The first drawing machine 31 receives the filaments extruded from the discharge end of the die head 214 and conveys the filaments to the oil bath drawing furnace 32 for drawing and oil immersion treatment.

[0061] The second drawing machine 33 receives the filaments exported from the oil bath drawing furnace 32 and transports the filaments to the steam drawing furnace 34 for drawing treatment.

[0062] The third drawing machine 35 receives the fine filaments discharged from the steam drawing furnace 34 to obtain polyester fibers.

[0063] In some embodiments, the oil bath drawing furnace 32 includes an oil bath 321, a plurality of conveying rollers 322 and a second heating assembly 323. The oil bath 321 is provided with an oil agent, the conveying rollers 322 are rotatably connected to the oil bath 321, and the filaments are wound around the conveying rollers 322 so that the filaments are immersed in the oil agent.

[0064] The oil bath 321 is divided into a first oil bath 321a and a second oil bath 321b. The second heating component 323 is disposed outside the oil bath 321 to keep the temperature inside the first oil bath 321a at 90-100°C and the temperature inside the second oil bath 321b at 150-160°C.

[0065] In some embodiments, the first oil bath 321a contains a first oiling agent, which, by mass parts, includes 70-80 parts paraffin oil, 20-30 parts penetrant, 10-15 parts polyethylene glycol, 3-5 parts KH550, 2-3 parts lubricant, and 7-9 parts antistatic agent; the polyethylene glycol has a molecular weight of 400-600.

[0066] The second oil bath 321b contains a second oiling agent, which, by mass parts, includes 70-80 parts paraffin oil, 20-30 parts penetrant, 3-5 parts nano-SiO2, 2-3 parts dispersant, 2-3 parts lubricant, and 7-9 parts antistatic agent.

[0067] This application uses an oil bath drawing furnace 32 instead of a wire holding tank. The fine wire is immersed in oil in the oil bath drawing furnace 32. By using high temperature and high concentration of oil agent in the oil bath drawing furnace 32, the oil agent can combine with the fine wire in a short time, which greatly shortens the oil immersion time.

[0068] The raw materials used in this invention are waste polyester bottle flakes and waste polyester textile foam. Due to the presence of impurities in waste polyester and the volatilization of small molecules during processing, the surface of polyester fibers obtained by conventional methods is relatively rough, and the diameter distribution of polyester fibers is relatively wide, resulting in poor uniformity of polyester fiber evenness, which affects the quality of polyester fibers. In addition, polyester fibers prepared from waste polyester have low crystallinity, resulting in low strength. Adding nucleating agents directly in the screw extrusion stage will cause partial crystallization during extrusion, affecting the subsequent tensile properties of polyester fibers. This invention employs a two-stage oil immersion process. The first immersion temperature is relatively low, and a penetrant, polyethylene glycol, and surfactant are added to the oil. Under the action of the penetrant, polyethylene glycol embeds between polyester molecular chains, weakening the intermolecular forces and enhancing the mobility of molecular chain segments. This relaxes the stress on the polyester surface, resulting in more uniform polyester yarn and a smoother surface under stretching, reducing the impact of recycled polyester on the surface roughness of polyester fibers. The second immersion temperature is higher, and nano-SiO2 nucleating agents and dispersants are added to the oil. The dispersant facilitates the uniform dispersion of nano-SiO2 in the oil. During the first immersion process, the polyester fiber surface is coated with KH550, which facilitates the adsorption of nano-SiO2 on the polyester fiber surface, increasing the crystallinity of the polyester fiber surface, thereby improving the smoothness and strength of the polyester fiber.

[0069] In some embodiments, a plurality of spinnerets 24 are arranged side by side at the discharge end of the die head 214, and the raw material melt in the barrel 211 is transported to the spinneret 24 by the screw 212 and extruded to form fine filaments;

[0070] Each spinneret 24 has 20,000 to 30,000 spinneret holes with a diameter of 0.1 to 0.7 mm.

[0071] In some embodiments, the one-step polyester manufacturing system further includes a post-processing unit 6, which includes a filament stacking machine 61, a crimping machine 63, a heat setting oven 64, a cutting machine 65, and a packaging machine 66 arranged sequentially along the material conveying direction, for sequentially performing filament stacking, crimping, setting, cutting, and packaging processes on the polyester fibers exported from the drawing unit 3.

[0072] Secondly, embodiments of this application provide a one-step polyester manufacturing method, comprising the following steps:

[0073] The batching unit 1 mixes the raw materials in proportion to obtain a mixture;

[0074] The mixture is heated and melted into a first melt using a screw extruder 21. A vacuum exhaust mechanism 22 removes moisture and volatile gases from the first melt to obtain a second melt, the moisture content of which is less than 0.01%.

[0075] The second melt is extruded through screw extruder 21 to form fine filaments;

[0076] The filaments are drawn and oil-immersed in a drawing unit to obtain polyester fibers. The oil immersion process includes a first oil immersion and a second oil immersion. The first oil immersion temperature is 90-100℃ and the oil immersion time is 5-10s. The second oil immersion temperature is 150-160℃ and the oil immersion time is 10-20s.

[0077] In some embodiments, the raw materials, by mass fraction, include 40-50 parts of waste polyester bottle flakes, 30-45 parts of waste polyester textile foam, 0.2-0.5 parts of composite antioxidant, 0.3-0.8 parts of fatty acid ester lubricant, 0.5-0.8 parts of nano calcium oxide, and 3-5 parts of color masterbatch.

[0078] The following are some specific embodiments. It should be noted that the embodiments described below are exemplary and are only used to explain this application, and should not be construed as limiting this application. Where specific techniques or conditions are not specified in the embodiments, they shall be performed in accordance with the techniques or conditions described in the literature in this field or according to the product instructions. Reagents or instruments whose manufacturers are not specified are all conventional products that can be obtained commercially.

[0079] Example 1

[0080] A one-step polyester manufacturing system, such as Figure 1 As shown, it includes a batching unit 1, a vacuum screw extrusion unit 2, and a drawing unit 3. The batching unit 1 includes a hopper 11 and a feeder 12. The raw materials are mixed evenly in the batching unit 1 to obtain a mixture, which is then conveyed to the feed end of the vacuum screw extrusion unit 2. The raw materials include 40 parts of waste polyester bottle flakes, 45 parts of waste polyester textile foam, 0.2 parts of composite antioxidant, 0.8 parts of fatty acid ester lubricant, 0.5 parts of nano calcium oxide, and 5 parts of color masterbatch.

[0081] The vacuum screw extrusion unit 2 includes a screw extruder 21 and a vacuum exhaust mechanism 22. The screw extruder 21 includes a barrel 211, a screw 212, and a die head 214. The screw 212 is coaxially arranged in the inner cavity of the barrel 211. A drive motor 213 is fixedly connected to the screw 212, and the drive motor 213 drives the screw 212 to rotate inside the barrel 211. After the raw material enters from the feed port of the barrel 211, it is conveyed to the die head 214 along the barrel 211 under the action of the screw 212. The barrel 211 of the screw extruder 21 includes a feed section, a compression section, a vacuum section, and a metering section arranged sequentially along the raw material conveying direction. An exhaust port 23 is opened on the inner wall of the vacuum section of the barrel 211. The vacuum exhaust mechanism 22 is fixedly connected to the barrel 211 and communicates with the inner cavity of the barrel 211 through the exhaust port 23. The screw extruder 21 heats and melts the mixture into a first melt in the feeding section and compression section, and then conveys it to the vacuum section.

[0082] The vacuum exhaust mechanism 22 is a water jet vacuum pump. The vacuum chamber of the water jet vacuum pump is connected to the barrel 211 through the exhaust port 23. The water jet vacuum pump controls the vacuum degree of the vacuum section to be <0.09Mpa. The water jet vacuum pump removes the water and volatile gases in the first melt to obtain the second melt. The water content in the second melt is less than 0.01%.

[0083] The barrel 211 is provided with a first heating component 215. The first heating component 215 includes an electric heating wire and a control system. The heating temperature of the electric heating wire is controlled by the control system. The temperature of the feeding section is controlled to be 230°C, the temperature of the compression section is controlled to be 280°C, the temperature of the vacuum section is controlled to be 260°C, and the temperature of the metering section is controlled to be 280°C.

[0084] The feed inlet of the die head 214 is connected to the discharge outlet of the barrel 211. Six spinnerets 24 are arranged side by side at the discharge end of the die head 214. The screw extruder 21 melts the raw material and extrudes it through the spinnerets 24 to form a liquid stream. After cooling, the liquid stream forms filaments. Each spinneret 24 has 20,000 spinneret holes with a diameter of 0.5 mm. Below the spinnerets 24 are a feed roller 4 and a front oiling roller 5. The filaments ejected from the six spinnerets 24 are oiled by the front oiling roller 5 and then collected by the conveyor roller 322 at the drawing unit 3 for drawing.

[0085] The drawing unit 3 includes a first drawing machine 31, an oil bath drawing furnace 32, a second drawing machine 33, a steam drawing furnace 34, and a third drawing machine 35 connected in sequence via filaments. The first drawing machine 31 receives the filaments extruded from the discharge end of the die head 214 and conveys them to the oil bath drawing furnace 32 for drawing and oil immersion treatment. The second drawing machine 33 receives the filaments discharged from the oil bath drawing furnace 32 and conveys them to the steam drawing furnace 34 for drawing treatment. The third drawing machine 35 receives the filaments discharged from the steam drawing furnace 34 to obtain polyester fibers. The speeds of the first drawing machine 31, the second drawing machine 33, and the third drawing machine 35 are 8 m / min, 40 m / min, and 50 m / min, respectively; the draw ratio is 3.

[0086] The oil bath drawing furnace 32 includes an oil bath 321, a conveying roller 322, and a second heating component 323. The oil bath 321 contains an oil solution. The conveying roller 322 is rotatably connected inside the oil bath 321. Fine wires are wound around the conveying roller 322. The conveying roller 322 is located in the oil solution, so that the fine wires are immersed in the oil bath 321 for oil immersion. The second heating component 323 is fixedly connected outside the oil bath 321. The second heating component 232 is an electric heating wire.

[0087] The oil bath 321 is divided into a first oil bath 321a and a second oil bath 321b. The second heating component 323 is disposed outside the oil bath 321 to keep the temperature inside the first oil bath 321a at 90-100°C and the temperature inside the second oil bath 321b at 150-160°C.

[0088] A steam drawing furnace 34 is provided between the second drawing machine 33 and the third drawing machine 35. The steam keeps the filament soft and plastic. The steam penetrates into the interior of the filament, weakens the intermolecular forces, and helps the molecular chains slide and align along the drawing direction, thereby improving the drawing efficiency and fiber mechanical properties.

[0089] The discharge end of the third drawing machine 35 is equipped with a post-processing unit 6. The post-processing unit 6 includes a filament stacking machine 61, a rear oil roller 62, a crimping machine 63, a heat setting oven 64, a cutting machine 65, and a packaging machine 66 arranged sequentially along the polyester fiber feeding direction. The post-processing unit 6 will perform filament stacking, crimping, setting, cutting, and packaging on the polyester fibers exported from the drawing unit 3.

[0090] A one-step polyester manufacturing method includes the following steps:

[0091] The hopper in batching unit 1 mixes 40 parts of waste polyester bottle flakes, 45 parts of waste polyester textile foam, 0.2 parts of composite antioxidant, 0.8 parts of fatty acid ester lubricant, 0.5 parts of nano calcium oxide and 5 parts of color masterbatch in proportion to obtain a mixture. The mixture is fed into screw extruder 21 through a feeder.

[0092] After the mixture enters the screw extruder 21, the rotating screw 212 propels it forward in the screw channel. It is initially softened at the preheating temperature of 230-250°C in the feeding section, and then enters the high-temperature compression section of 260-280°C. Under the combined action of shearing by the screw 212 and heating by the barrel 211, it is completely melted and plasticized, becoming a uniform first melt. Subsequently, the first melt enters the vacuum section, where moisture and low-molecular-weight volatiles are extracted by the vacuum exhaust mechanism 22, reducing the moisture content to below 0.01% to form a second melt. Finally, the second melt is filtered for impurities by the filter screen of the die head 214 and evenly distributed by the distribution plate, and then extruded from the spinneret holes on the spinneret 24 to form a liquid stream. After cooling, the liquid stream forms fine filaments.

[0093] The filaments are drawn and oil-immersed in the drawing unit 3. The filaments are sequentially drawn in the first drawing machine 31, oil bath drawing furnace 32, second drawing machine 33, steam drawing furnace 34 and third drawing machine 35, undergoing first drawing, oil immersion drawing, second drawing, steam drawing and third drawing. After cooling and setting, polyester fibers are obtained. The first drawing, second drawing and third drawing speeds are 8m / min, 40m / min and 50m / min respectively, and the drawing ratio is 3 times.

[0094] The first oil bath 321a contains a first oiling agent, which, by mass parts, includes 80 parts paraffin oil, 20 parts leveling agent, 15 parts polyethylene glycol, 3 parts KH550, 2 parts lubricant glyceryl stearate, and 9 parts antistatic agent; the molecular weight of polyethylene glycol is 400, the first oil immersion temperature is 100℃, and the oil immersion time is 5s;

[0095] The second oil bath 321b contains a second oiling agent, which, by mass fraction, includes 50 parts paraffin oil, 20 parts penetrant leveling agent, 5 parts nano-SiO2, 2 parts dispersant polyether-modified siloxane, 3 parts lubricant stearic acid monoglyceride, and 7 parts antistatic agent. The second oil immersion temperature is 160℃, and the oil immersion time is 10s.

[0096] Polyester fibers are processed in post-processing unit 6 for filament stacking, crimping, setting, cutting and packaging.

[0097] In this embodiment 1, the polyester manufacturing system occupies an area of ​​1200 square meters, the time from material feeding to product output is 30 minutes, the output of a single screw 212 is 12 tons / day, the polyester properties are a breaking strength of 3.5 CN / dtex, a surface roughness Ra of 56 nm, a yarn evenness CV value of 0.9%, and requires 15 workers.

[0098] The traditional polyester manufacturing system occupies an area of ​​4357.3 square meters. Using the traditional polyester manufacturing method, the time from material input to product output is 2 days. The output of a single 212 screw is 6-7 tons / day. The polyester properties are a breaking strength >2.5CN / dtex. The required workforce is 20 people.

[0099] Example 2

[0100] The differences between Example 2 and Example 1 are as follows:

[0101] The first oil bath 321a contains a first oiling agent, which, by mass parts, includes 70 parts paraffin oil, 30 parts penetrant leveling agent, 10 parts polyethylene glycol, 5 parts KH550, 3 parts lubricant glyceryl stearate, and 7 parts antistatic agent; the polyethylene glycol has a molecular weight of 600, the first oil immersion temperature is 90℃, and the oil immersion time is 10s;

[0102] The second oil bath 321b contains a second oiling agent, which, by mass fraction, includes 40 parts paraffin oil, 30 parts penetrant leveling agent, 3 parts nano-SiO2, 3 parts dispersant polyether-modified siloxane, 2 parts lubricant stearic acid monoglyceride, and 9 parts antistatic agent. The second oil immersion temperature is 150°C, and the oil immersion time is 20 seconds.

[0103] The polyester prepared in Example 2 has the following properties: breaking strength of 3.6 CN / dtex, surface roughness Ra of 52 nm, and yarn uniformity CV of 0.8%.

[0104] Comparative Example 1

[0105] The difference between Comparative Example 1 and Example 1 is that the oil immersion treatment is a one-stage process, with the first and second oil agents being the same. The specific steps are as follows:

[0106] The oiling agent consists of 80 parts paraffin oil, 20 parts penetrant leveling agent, 15 parts polyethylene glycol, 3 parts KH550, 2 parts lubricant glyceryl stearate, 5 parts nano-SiO2, 2 parts dispersant polyether modified siloxane, and 9 parts antistatic agent; the molecular weight of polyethylene glycol is 400, the first oil immersion temperature is 100℃, and the oil immersion time is 15s.

[0107] The polyester fiber prepared in Comparative Example 1 exhibited a breaking strength of 2.3 CN / dtex, a surface roughness Ra of 124 nm, and a yarn evenness CV value of 3.8%. This demonstrates that the two-stage oil bath method described in this application can improve the surface smoothness and yarn evenness of polyester fibers, and enhance their strength.

[0108] In summary, the one-step polyester manufacturing method described in this application can significantly improve polyester production efficiency. The entire production system is fully automated, saving substantial labor costs and land area. It should be noted that this application is not limited to the above-described embodiments. The above embodiments are merely examples, and any embodiments with the same essential structure and achieving the same effect as the technical concept within the scope of this application are included in the technical scope of this application. Furthermore, various modifications to the embodiments that can be conceived by those skilled in the art, and other ways of constructing embodiments by combining some of the constituent elements, without departing from the spirit of this application, are also included in the scope of this application.

Claims

1. A one-step polyester manufacturing system, characterized in that, include: Ingredient preparation unit; A vacuum screw extrusion unit includes a screw extruder and a vacuum exhaust mechanism. The screw extruder includes a barrel, a screw, and a die head. The screw is coaxially disposed in the inner cavity of the barrel. The feed inlet of the die head is connected to the discharge outlet of the barrel. The vacuum exhaust mechanism is connected to the barrel. The discharge outlet of the batching unit is connected to the feed inlet of the barrel. The drawing unit is connected to the discharge end of the die head and is used to receive the filaments extruded by the vacuum screw extrusion unit and perform drawing and oil impregnation treatment to obtain polyester fibers. The barrel includes a feeding section, a compression section, a vacuum section and a metering section arranged sequentially along the raw material conveying direction. An exhaust hole is provided on the inner wall of the vacuum section of the barrel. The vacuum exhaust mechanism is fixedly connected to the barrel and communicates with the inner cavity of the barrel through the exhaust hole. The vacuum exhaust mechanism is a water jet vacuum pump, and the vacuum exhaust mechanism controls the vacuum level of the vacuum section to be <0.09 MPa; The barrel is provided with a first heating component, which controls the temperature of the feeding section to be 230-250°C, the temperature of the compression section to be 260-280°C, the temperature of the vacuum section to be 260-270°C, and the temperature of the metering section to be 270-280°C. The drawing unit includes a first drawing machine, an oil bath drawing furnace, a second drawing machine, a steam drawing furnace, and a third drawing machine arranged sequentially along the material conveying direction; The first drawing machine receives the filaments extruded from the discharge end of the die head and transports the filaments to the oil bath drawing furnace for drawing and oil immersion treatment; The second drawing machine receives the filaments exported from the oil bath drawing furnace and transports the filaments to the steam drawing furnace for drawing processing; The third drawing machine receives the fine filaments discharged from the steam drawing furnace to obtain polyester fibers; The oil bath drawing furnace includes an oil bath tank, several conveying rollers, and a second heating component. The oil bath tank contains an oil agent, the conveying rollers are rotatably arranged inside the oil bath tank, and the filaments are wound around the conveying rollers and immersed in the oil agent. The oil bath is divided into a first oil bath and a second oil bath. The second heating component is located outside the oil bath and is used to keep the temperature inside the first oil bath at 90-100°C and the temperature inside the second oil bath at 150-160°C. The first oil bath contains a first oiling agent, which, by mass parts, comprises 70-80 parts paraffin oil, 20-30 parts penetrant, 10-15 parts polyethylene glycol, 3-5 parts KH550, 2-3 parts lubricant, and 7-9 parts antistatic agent; the polyethylene glycol has a molecular weight of 400-600. The second oil bath contains a second oiling agent, which, by mass parts, includes 70-80 parts paraffin oil, 20-30 parts penetrant, 3-5 parts nano-SiO2, 2-3 parts dispersant, 2-3 parts lubricant, and 7-9 parts antistatic agent.

2. The one-step polyester manufacturing system according to claim 1, characterized in that, The discharge end of the die head is provided with multiple spinnerets arranged in parallel. The raw material melt in the barrel is transported to the spinnerets by the screw and extruded to form fine filaments. Each of the spinnerets is provided with a plurality of spinneret holes, the diameter of which is 0.1 to 0.7 mm.

3. The one-step polyester manufacturing system according to claim 1, characterized in that, The one-step polyester manufacturing system also includes a post-processing unit, which includes a yarn stacking machine, a crimping machine, a heat setting oven, a cutting machine, and a packaging machine arranged sequentially along the material conveying direction. These machines are used to sequentially stack, crimp, set, cut, and package the polyester fibers produced by the drawing unit.

4. A one-step polyester manufacturing method, characterized in that, The process involves preparing the polyester using the one-step polyester manufacturing system described in any one of claims 1 to 3, comprising the following steps: The batching unit mixes the raw materials in a certain proportion to obtain a mixture; The mixture is heated and melted into a first melt using a screw extruder. The vacuum exhaust mechanism removes moisture and volatile gases from the first melt to obtain a second melt, wherein the moisture content of the second melt is less than 0.01%. The second melt is extruded into filaments using a screw extruder; The filaments are drawn and oil-immersed in the drawing unit to obtain polyester fibers; the oil immersion treatment includes a first oil immersion and a second oil immersion, wherein the first oil immersion temperature is 90-100℃ and the oil immersion time is 5-10s; the second oil immersion temperature is 150-160℃ and the oil immersion time is 10-20s.

5. The one-step polyester manufacturing method according to claim 4, characterized in that, By weight, the raw materials include 40-50 parts of waste polyester bottle flakes, 30-45 parts of waste polyester textile foam, 0.2-0.5 parts of composite antioxidant, 0.3-0.8 parts of fatty acid ester lubricant, 0.5-0.8 parts of nano calcium oxide, and 3-5 parts of color masterbatch.

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