Processing method of spherical spinneret and spherical spinneret

Abstract

The application discloses a kind of spherical spinneret processing method and spherical spinneret, processing method includes obtaining spinneret semi-product, the first semi-product is obtained by pretreating the spinneret semi-product, wherein the pretreatment includes once punching;After the through hole of the first semi-product is filled and solidified, the first semi-product is pressed using spherical composite mould, and the second semi-product is obtained;The hole filler of the second semi-product is removed, and the through hole of the second semi-product is punched at least twice, and the spherical spinneret is obtained after post-processing after each punching.

Description

Technical Field

[0001] This invention relates to the field of carbon fiber spherical spinnerets, and more particularly to a processing method for spherical spinnerets and a spherical spinneret itself. Background Technology

[0002] The function of a spinneret is to transform a viscous polymer melt or solution into a fine stream with a specific cross-sectional shape through micropores, which is then solidified by a coagulation medium such as air or a coagulant to form filaments. Spinning components are required in the production of thermal and moisture-comfort functional composite fibers.

[0003] Depending on the application conditions, carbon fiber spherical spinnerets are manufactured from different materials. Commonly used carbon fiber spinnerets employ circular planar and spherical structures, primarily used in spinning machines with small tonnage. As the market demand for spinning machine capacity increases, the number of spinneret orifices has increased from tens to thousands, and further to tens of thousands. Carbon fiber spinnerets need to operate under high temperatures and pressures, therefore requiring pressure resistance, corrosion resistance, and sufficient mechanical strength. The main technological challenge in producing carbon fiber spherical spinnerets lies in whether to produce the spherical blank first and then punch it, or to punch the blank on a flat surface first and then press it into a spherical shape. If the spinneret blank is processed into a spherical shape first and then punched, the requirements for the spinneret blank are very high. Its dimensions must meet the drawing requirements, and the thickness and flatness of the processed spherical spinneret must not exceed 0.01. When the area of ​​the spinneret is large, it is difficult to achieve the required stamping and shaping processes. In addition, the polishing process will greatly increase the manufacturing cost, and the requirements for the punching equipment are very high. If the blank is punched on a flat spinneret blank first and then processed into a spherical shape, it is difficult to control the stretching deformation of the spinneret holes during the transformation from a flat surface to a spherical surface, and it is uncertain whether the subsequent punching can meet the production requirements. Summary of the Invention

[0004] The main objective of this invention is to provide a method for processing a spherical spinneret and a spherical spinneret, in order to solve the technical problems described in the background section.

[0005] In a first aspect, the present invention provides a method for processing a spherical spinneret, comprising: Obtain a spinneret semi-finished product, and pre-treat the spinneret semi-finished product to obtain a first semi-finished product, wherein the pre-treatment includes one punching. After filling and curing the through holes of the first semi-finished product, the first semi-finished product is pressed and shaped using a spherical composite mold to obtain the second semi-finished product. Remove the filler material from the holes of the second semi-finished product, punch the same position of the second semi-finished product at least twice, and perform post-processing after each punching to obtain the spherical spinneret.

[0006] In one embodiment, the step of removing the filler from the holes of the second semi-finished product includes: After soaking the second semi-finished product in a preset reagent for a preset time, the second semi-finished product is taken out and rinsed.

[0007] In one embodiment, the step of removing the filler from the holes of the second semi-finished product includes: After heating the second semi-finished product to a preset temperature, high-pressure airflow is used to blow away the pores of the second semi-finished product.

[0008] In one embodiment, the step of punching the shaped blank to obtain the first semi-finished product includes: The spinneret semi-finished product is installed on an automatic punching machine tool, and punched once according to the first punching frequency, the first punching stroke and the first punching direction to form blind holes. The semi-finished spinneret after punching is removed from the automatic punching machine and subjected to cleaning, grinding and washing processes in sequence to obtain the first semi-finished product, wherein the grinding process processes the blind hole into a through hole.

[0009] In one embodiment, the step of punching the through-hole of the second semi-finished product at least twice, and performing post-processing after each punching to obtain the spherical spinneret includes: The second semi-finished product is installed on an automatic punching machine, and the through hole of the second semi-finished product is punched once according to the second punching stroke, the second punching frequency, and the second punching direction. The punched second semi-finished product is installed on an automatic punching machine for the first post-processing. The second semi-finished product after the first post-processing is removed from the automatic punching machine. The through hole of the second semi-finished product is punched once according to the third punching frequency, the preset punching force and the second punching direction. The second semi-finished product after punching is removed from the automatic punching machine and subjected to a second post-processing to obtain the spherical spinneret.

[0010] In one embodiment, the step of filling and curing the first semi-finished product with pores, and then using a spherical composite mold to shape the first semi-finished product to obtain the second semi-finished product can be replaced by: After the through-pores of the first semi-finished product are filled and cured with polyurethane microporous elastomer, the first semi-finished product is pressed into shape using a spherical composite mold to obtain the second semi-finished product.

[0011] In one embodiment, the step of obtaining the spinneret semi-finished product includes: Obtain a sheet material, and perform cold rolling on the sheet material to obtain a sheet material of a preset size; According to the preset dimensions, a blanking and stamping compound die is obtained, and the sheet metal of the preset dimensions is stamped to obtain a blank; The blank is shaped using a shaping mold to obtain a spinneret semi-finished product.

[0012] In one embodiment, the sheet material is stainless steel or tantalum.

[0013] In a second aspect, the present invention also provides a spherical spinneret, which is manufactured by the processing method described in any one of the first aspects.

[0014] This invention employs a processing method of punching holes, filling them, and then pressing them (to form a spherical surface). Before pressing the spherical spinneret, the through-holes are filled and cured. This protects the structural integrity of the through-holes (pre-punched holes) during the pressing process, preventing hole wall collapse, deformation, or positional displacement caused by pressure during spherical forming. This ensures the initial positional accuracy of the holes. Furthermore, the sequence of punching holes before pressing avoids uneven contact between the mold and the sheet metal caused by the curved surface of the spherical surface when pressing first and then punching. This reduces plastic deformation deviations of the sheet metal during pressing and improves overall structural stability. Simultaneously, the through-holes are punched at least twice, employing a step-by-step processing mode. This allows for gradual correction of dimensional and shape errors (such as roundness and perpendicularity) in the holes. Compared to single-punching, this reduces defects such as burrs and cracks on the hole walls caused by excessive instantaneous material stress. Attached Figure Description

[0015] Figure 1 This is a schematic flowchart of a method for processing a spherical spinneret according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of the spherical spinneret before forming in one embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of a spherical spinneret in one embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of a spherical spinneret in one embodiment of the present invention; Figure 5 for Figure 4 Enlarged view of section A in the middle; Explanation of component symbols in the diagram: 1. Inlet surface; 2. Outlet surface; 3. Spinneret. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0017] It is important to understand that the carbon fiber spinneret (also known as a carbon fiber spinning cap) described in the background technology is a metal / alloy component with a precision micropore array. Its main function is to force the pretreated viscous carbon fiber precursor (such as polyacrylonitrile PAN, pitch, adhesive, etc.) through the micron-level micropores on its surface to form a continuous fine stream with a specific cross-sectional shape (circular, irregular, etc.). The fine stream then enters a coagulation bath (solution spinning) or a cooling environment (melt spinning) to solidify, and finally forms carbon fiber filaments.

[0018] Firstly, referring to Figure 1 This invention provides a method for processing a spherical spinneret, comprising: S110, Obtain a spinneret semi-finished product, pre-treat the spinneret semi-finished product to obtain a first semi-finished product, wherein the pre-treating includes a single punching. Obtain a semi-finished spinneret made from sheet metal, such as... Figure 2 As shown (outer diameter φA, inner diameter ΦB, height H, thickness T), its shape resembles a hat with an edge, but it does not have spinneret holes 3 inside. The spinneret cap semi-finished product is then pre-processed to obtain the first semi-finished product. This pre-processing includes at least one punching operation. This punching can be positioned using a high-definition camera, and a punching device is used to punch holes inside the spinneret cap semi-finished product. The holes in the pre-processed spinneret semi-finished product are through holes, i.e., spinneret holes 3.

[0019] Among them, the spinneret semi-finished product refers to the semi-finished product of the spinneret before it is perforated and formed.

[0020] S120, after filling and curing the through holes of the first semi-finished product, the first semi-finished product is pressed using a spherical composite mold to obtain the second semi-finished product; The filler is a high molecular polymer. For example, during filling, the first semi-finished product is placed in a self-made sealing fixture, and liquid filler is placed on the thread-in side 1 of the first semi-finished product. The filler is spread evenly, and after the door of the self-made sealing fixture is closed, gas is injected into it and pressurized to 3-4 MPa. The pressure is maintained for 8 hours to ensure that the filler fills all the holes. After the filler has cured, the first semi-finished product is placed in a spherical composite mold and a press is used to shape the first semi-finished product. During the shaping, the press is 50 tons, the pressure value is 35 MPa, and the pressure holding time is about 30 seconds.

[0021] The process involves determining the spherical composite mold based on the requirements (such as dimensions) of the spherical spinneret. For example, the inner diameter of the spinneret semi-finished product is important. Different spherical spinnerets correspond to different spherical composite molds. Without filler, the surface layer of the first semi-finished product is stretched to conform to the spherical curvature, and the inner layer is compressed to compensate for the deformation of the surface layer. The through-hole, as a hollow and weak area, is compressed (hole diameter shrinks), stretched (hole diameter increases), or shifted (position changes) with the flow of metal. For example, a cylindrical through-hole may deform into an elliptical shape, and the outlet and inlet of the hole may shift in different directions. The axis of the through-hole is no longer perpendicular to the tangent of the curved surface, affecting the wire output effect of the spherical spinneret. The step of filling before pressing reduces the deformation of the hole during pressing, keeping the hole changes within a controllable range and ensuring that the relative position of the hole remains unchanged, without affecting the subsequent hole processing and the wire output effect of the spinneret.

[0022] S130, remove the filler in the hole of the second semi-finished product, punch the through hole of the second semi-finished product at least twice, and perform post-processing after each punching to obtain the spherical spinneret.

[0023] Spherical spinneret Figure 3-5 As shown, the outer diameter is φA, the inner diameter is ΦB, the height is h, the thickness is t, and the radius of the sphere (in the spherical spinneret) is SR, where h is greater than H, t (0.2mm ≤ t ≤ 2mm) is less than T, and the roughness of the inlet surface 1 and the outlet surface 2 is ≤0.1µm, the roughness inside the spinneret 3 is ≤0.1µm, and the dimensional accuracy of the spinneret 3 is φ0.05±0.002mm; the removal of the filler inside the hole can be achieved by physical / chemical methods, and the through holes of the second semi-finished product are subjected to at least Double punching refers to punching each through hole at least twice in step S110. Double punching not only strengthens the hardness and reduces roughness within the hole, but also corrects the hole shape, adjusting for minor deformations that may occur during the forming process. The resulting spherical spinneret has a spinneret hole inner surface roughness ≤0.1µm and a hole diameter accuracy of φ0.05±0.002mm. For example, a 150mm outer diameter spinneret semi-finished product produced using 0.7mm tantalum material (such as...) Figure 2 As shown), the spherical spinneret obtained after steps S110, S120 and S130 (e.g.) Figure 3-5 (As shown) The number of spinnerets is in the tens of thousands, the inner surface roughness of the spinneret 3 holes is ≤0.1um, the hole diameter accuracy is φ0.05±0.002mm, and the working pressure is not less than 2MPa.

[0024] In this embodiment, a processing method of punching, filling, and then pressing is adopted. The holes are filled and cured before pressing the spherical spinneret. This method can protect the structural integrity of the pre-punched holes during the pressing process, prevent the hole walls from collapsing, deforming, or shifting due to the pressure during spherical forming, and ensure the initial positional accuracy of the holes. The order of punching before pressing avoids the problem of uneven contact between the mold and the sheet metal caused by the curved surface of the spherical surface when pressing before punching. This reduces the plastic deformation deviation of the sheet metal during the pressing process and improves the overall structural stability. At the same time, the step-by-step processing mode of "punching at least twice" in the same through hole can gradually correct the size error and shape deviation of the hole (such as roundness and perpendicularity). Compared with single punching, it can reduce defects such as burrs and cracks on the hole walls caused by excessive instantaneous force on the material.

[0025] In one embodiment, step S130, removing the filler from the holes of the second semi-finished product, includes: S1301, after soaking the second semi-finished product in a preset reagent for a preset time, take out the second semi-finished product and rinse it.

[0026] The chemical properties of the pre-set reagent are matched with those of the pore filler, which can efficiently dissolve / destroy the filler without reacting with the substrate (such as metal) of the second semi-finished product, thus avoiding corrosion of the spherical surface or pore wall. The filler can be set as a polyurethane microporous elastomer, which is a polyurethane elastic material with a special microporous structure. Its main raw materials include oligomeric polyols, polyisocyanates, chain extenders and foaming agents, which combine the lightweight cushioning of foam plastics and the high strength and wear resistance of elastomers.

[0027] Specifically, polyurethane microporous elastomers include thermosetting polyurethane and thermoplastic polyurethane. When using thermosetting polyurethane microporous elastomers, strong solvents or chemical reagents (such as a mixture of dimethylformamide (DMF) and ethanol (volume ratio 1:1) and a 10%-15% sodium hydroxide (NaOH) solution (heated to 60-80℃)) can be used to disrupt the cross-linking structure of the thermosetting polyurethane, causing it to "swell and become brittle" before detaching. The spinneret is completely immersed in the pre-set reagent, sealed, and placed in a 60-80℃ constant temperature water bath (to accelerate swelling / decomposition) for 8-24 hours (observing every 4 hours until the elastomer softens significantly). The spinneret is then removed using specialized equipment, and the spinneret holes are gently brushed with a soft brush or blown away with compressed air. If residue remains, it is soaked again in DMF for 1-2 hours, and the cleaning process is repeated. After cleaning, a deionizing agent is used. Rinse the spinneret 3-5 times with deionized water, then soak it in ethanol for 10 minutes (to remove residual reagents), and finally dry it in a 60°C oven. When using thermoplastic polyurethane microporous elastomer, specific reagents (solvents) that directly dissolve the pore filler can be used, such as dimethylformamide (DMF), tetrahydrofuran (THF), and methyl ethyl ketone (MEK): Immerse the spinneret in room temperature DMF (no heating required; thermoplastic TPU will dissolve in room temperature DMF in 2-4 hours), seal it, and let it stand. Gently shake the container every hour to accelerate the solvent penetration into the spinneret orifices 3. Once the elastomer is completely dissolved (observe that there is no residue in the spinneret orifices 3), remove the spinneret, rinse it twice with THF (to remove residual DMF and dissolved TPU), then rinse it three times with deionized water, and dry it in a 50°C vacuum oven (to avoid solvent residue affecting subsequent use).

[0028] In this embodiment, by using a pre-set reagent, chemical action can be used to penetrate deep into the tiny gaps inside the hole, which can more thoroughly remove the filler than mechanical cleaning (such as scraping). It is especially suitable for spinneret structures with small orifice diameters and deep holes, avoiding the impact of residual filler on the accuracy of subsequent punching. The soaking + rinsing process is easy to standardize, and a stable cleaning effect can be achieved by adjusting parameters such as solvent concentration and soaking time. It is suitable for automated operation in mass production (such as assembly line soaking tanks and rinsing devices), improving processing efficiency.

[0029] In one embodiment, step S130, removing the filler from the holes of the second semi-finished product, includes: S1301, after heating the second semi-finished product to a preset temperature, use high-pressure airflow to blow through the through holes of the second semi-finished product.

[0030] Heating to a preset temperature is to remove filler from the second semi-finished product, and this preset temperature should be below the substrate stress-sensitive temperature of the second semi-finished product.

[0031] For example, when using thermosetting polyurethane microporous elastomer as filler, use compressed air (0.3-0.5MPa) to blow away the dust on the spinneret surface and the openings of spinneret orifices 3 to avoid interference from impurities. Place the spinneret in a muffle furnace (or an inert gas protected furnace to avoid slight oxidation of stainless steel), heat to 380-450℃ (critical temperature: below the oxidation temperature of stainless steel, above the carbonization temperature of polyurethane), and hold for 2-4 hours (adjust according to the thickness of the elastomer; if the amount of filler in the micropores is small, it can be shortened to 1-2 hours). After naturally cooling to room temperature, gently brush the spinneret orifices 3 with a soft brush (such as a nylon brush). The carbonized polyurethane will fall off in powder form. If there is residue in the orifice, blow it out with compressed air in the opposite direction (blowing from the back of the spinneret), or gently poke it out with a PTFE rod with a diameter slightly smaller than that of the spinneret orifice 3 (avoid scratching the orifice diameter). If an air atmosphere muffle furnace is used, a slight oxidation may form on the stainless steel surface. The micro-oxide film (which does not affect the pore size) can be removed by wiping with ethanol later. Tantalum will form a stable oxide film at high temperatures in air (harmless and does not affect performance). At the same time, it is strictly forbidden to heat up too quickly (5-10℃ / min is recommended) to avoid the thermal expansion of the elastomer in the spinneret 3, which will cause deformation of the pore size. When the filler used is thermoplastic polyurethane microporous elastomer, put the spinneret into an oven and heat it to 180-200℃ (above the melting temperature but below the decomposition temperature). Keep it at this temperature for 30-60 minutes (the elastomer in the micropores is small and will melt in 30 minutes). Take out the spinneret (wear high-temperature resistant gloves) and immediately blow it in the opposite direction from the "non-filled side" of the spinneret with compressed air (0.2-0.3MPa). The molten polyurethane will flow out from the spinneret 3. After naturally cooling to below 80℃, wipe the surface of the spinneret 3 with a cotton cloth dipped in ethanol to remove the residual melt (ethanol can dissolve a small amount of TPU that has not completely flowed out).

[0032] In this embodiment, after the filler is softened or embrittled by heating, the high-pressure airflow can accurately remove the residue inside the hole. Compared with pure mechanical cleaning, it is more suitable for small and deep hole structures (such as spinneret micropores), avoiding scratches or deformation of the hole wall, ensuring the accuracy of the pore size. The airflow purging is a physical cleaning method, which does not generate chemical waste liquid and is more environmentally friendly. At the same time, it avoids problems such as substrate swelling and discoloration that may be caused by solvent soaking, reducing the scrap rate.

[0033] In other embodiments, physical removal methods may be used to remove the filler, such as peeling it off with a tool that matches the hole, or peeling it off after freezing and embrittlement (polyurethane elastomers lose elasticity and become brittle at low temperatures, at which point they can be removed by tapping or scraping).

[0034] In one embodiment, S110, the step of obtaining the spinneret semi-finished product includes: S1101, Obtain the sheet material, perform cold rolling on the sheet material to obtain the sheet material of the preset size; Raw metal sheets (such as stainless steel, tantalum, etc.) are processed into pre-formed blanks of preset dimensions through cold rolling, ensuring dimensional accuracy (length, width, and thickness deviation ≤ ±0.1mm), while improving the surface finish and hardness of the material to reduce subsequent stamping deformation. Specifically, the raw metal coil is inspected to confirm the thickness, and rust-preventive oil and impurities are removed from the surface of the coil. The coil is fixed on an uncoiler, and the sheet is guided into the working rolls of the cold rolling mill by guide rollers. The roll gap is adjusted to the initial set value, the cold rolling mill is started, and the rolling speed is set (adjusted according to the material hardness; the speed is reduced for higher hardness). "Multi-pass cold rolling" is used. The cold-rolled sheet is sent to a leveling machine, and the leveling pressure is set to eliminate warping. Then, the width is cut by a slitting machine (according to the blank width requirements), and the length is cut by a cross-cutting machine (1-2mm larger than the product size after blanking and stamping, leaving a stamping allowance).

[0035] Cold rolling can precisely control the thickness and flatness of sheet metal through plastic deformation. Compared with hot rolling, it is easier to achieve micron-level dimensional tolerances, providing a stable blank base for subsequent stamping and forming. This refines the grain size of the sheet metal, improves its strength, hardness and surface finish, reduces plastic deformation deviations in subsequent processing (such as stamping and forming), and enhances the structural stability of the finished product.

[0036] S1102, Obtain a blanking and stamping compound die according to the preset size, and stamp the sheet material of the preset size to obtain a blank; Match the blanking and stamping compound die to the dimensions of the spherical spinneret to be produced. Pass the cold-rolled sheet through the blanking and stamping compound die to complete both "blanking" (separating the product shape) and "preliminary shaping" (such as holes, slots, and other simple structures) in one pass, ensuring dimensional accuracy and burr-free product shape. Specifically, fix the lower die of the blanking and stamping compound die on the T-slot of the press table, and connect the press slide with the upper die fixing plate. Start the press in "jog mode" and adjust the slide stroke to the "bottom dead center" to ensure precise engagement of the positioning pins of the upper and lower dies. Use a die calibrator to check the punch-die clearance; if the clearance is uneven, adjust the die position. Set the press parameters according to the drawings, such as nominal pressure (25 tons (equipment rating)) and actual stamping pressure (90% of the rated pressure to avoid overload and damage to the die). The stamping speed (e.g., 10-15 times / min, adjusted according to product complexity) and stamping oil spraying (starting the automatic spraying device to spray extreme pressure stamping oil at the contact point between the die cutting edge and the blank) are adjusted. The cold-rolled blank is placed into the positioning groove of the lower die, and the pneumatic positioning pin pops out to fix the blank. The "automatic mode" of the punch press is started, and the slide moves the upper die downward. First, the sheet metal is compacted by the stripper plate, and then the shape of the sheet metal is sheared by the blanking cutting edge. At the same time, the forming punch completes the stamping of holes / grooves and other structures. When the slide moves upward, the stripper plate removes the stamped product from the punch, and the scrap falls into the scrap collection device. In addition, the sheet metal needs to be inspected. For example, for every 10 products stamped, 1 piece is randomly selected and its shape is checked with calipers. The burrs are checked with an optical burr detector. If the dimensional deviation is out of tolerance, the die positioning is adjusted. If the burrs are too large, the die cutting edge is ground.

[0037] S1103, Using a shaping mold, the blank is shaped to obtain a spinneret semi-finished product; The blanking and stamping process involves shaping the product to eliminate internal stress and springback deformation (such as bending and warping) caused by stamping, ensuring the final dimensional accuracy and geometric tolerances meet the drawing requirements. Specifically: the lower die of the shaping mold is fixed on the press table, and the upper die is connected to the slider; the coaxiality of the upper and lower dies is ensured by guide pillars; the press is started in "jog mode," and the slider stroke is adjusted so that when the upper and lower dies are closed, the mold cavity completely fits the product blank (without gaps); press parameters such as nominal pressure (nominal pressure 50 tons, shaping pressure: 30MPa), holding time (approximately 20 seconds), and cooling system (to control the mold temperature at a certain level to prevent excessive temperature from increasing material springback) are set; the blanking and stamping product is then placed into the positioning cavity of the lower die. The elastic ejector lifts the blank, ensuring it fits snugly against the positioning surface. The press is then activated in semi-automatic mode, with the slide moving the upper die downwards. After contacting the blank, pressure is slowly increased to 30MPa, triggering the pressure holding timer. During the 20-second pressure holding period, the pressure sensor monitors the pressure in real time. If the pressure drops (e.g., due to poor sealing), the press automatically replenishes the pressure. After the pressure holding period, the slide moves upwards, and the elastic ejector ejects the shaped product. The product is then removed and placed in a qualified product box. Furthermore, product inspection is required. For example, for every 20 shaped products, one is randomly selected for flatness and parallelism testing using a laser interferometer, and the final dimensions are measured using calipers. If the form and position tolerances are out of tolerance, the pressure holding time is adjusted (extended to 22-25 seconds if springback is significant). If dimensional deviations are found, the mold cavity is fine-tuned (e.g., by using thin copper sheets to adjust the gap).

[0038] In one embodiment, step S110, which involves pre-treating the spinneret semi-finished product to obtain a first semi-finished product, includes: S1111, The spinneret semi-finished product is installed on an automatic punching machine tool, and the spinneret semi-finished product is punched once according to the first punching frequency, the first punching stroke and the first punching direction to form blind holes; The first punching stroke during punching is equal to the thickness of the spinneret. The first punching direction is perpendicular to the bottom surface of the spinneret semi-finished product. Due to the material properties, the punch will form a blind hole in the spinneret that is similar in shape to the punch (due to the material properties, blank material will accumulate at the outlet of the spinneret hole 3).

[0039] Specifically, the spinneret semi-finished product is installed on an automatic punching machine. The spinneret semi-finished product is required to be concentric with the automatic punching machine and have the same bottom mounting flatness. The spinneret semi-finished product is punched according to the first punching stroke of 0.8mm, the first punching frequency of 0.8 seconds / hole, and the first punching direction.

[0040] S1112, the semi-finished spinneret after punching is removed from the automatic punching machine and subjected to cleaning, grinding and washing processes in sequence to obtain the first semi-finished product, wherein the grinding process processes the blind hole into a through hole.

[0041] Specifically, the cleaning process (first time) includes: first, high-pressure water rinsing, then soaking in an immersion tank, then rinsing with warm water, then cleaning in an ultrasonic cleaner, and finally drying in a drying oven. For example, the spinneret semi-finished product is subjected to high-pressure water rinsing, then soaked in an immersion tank containing 30% degreasing powder for about 2 hours, then rinsed with 70℃ warm water for 10 minutes, then placed in an ultrasonic cleaner with a cleaning power of 1.0Hz for 30 minutes, and finally dried in a dryer with a drying temperature of 100℃ for about 1 hour; grinding includes: grinding the filament output surface of the product to achieve... The drawing requires, for example, the filament output surface of the cleaned spinneret semi-finished product to be ground for 1 hour using a grinding mill with a rotation speed of 15 r / min, wherein the grinding fluid used in the grinding mill contains 10% by mass of abrasive powder; the cleaning treatment (second time) includes: first high-pressure rinsing, then cleaning in an ultrasonic cleaner and drying in a drying oven. For example: the spinneret semi-finished product is high-pressure rinsed for 30 minutes, then placed in an ultrasonic cleaner with a cleaning power of 1.2 Hz for 30 minutes, and finally placed in a dryer with a drying temperature of 100℃ for about 1 hour.

[0042] After punching, the material properties cause the punch to form a blind hole in the spinneret that is similar in shape to the punch (due to the material properties, blank material will accumulate at the outlet of the spinneret hole 3). Subsequent grinding process turns the blind hole into a through hole.

[0043] In this embodiment, the pre-processing is the pre-processing of the spinneret hole 3, which initially opens the channel and uses the original plane as a reference to ensure the "initial position accuracy" of the first punching, so as to build a "correctable initial channel" for subsequent forming and secondary punching, and reduce the processing difficulty of subsequent processes.

[0044] In one embodiment, step S130, which involves punching the through-hole of the second semi-finished product at least twice and performing post-processing after each punching to obtain the spherical spinneret, includes: S1311, The second semi-finished product is installed on an automatic punching machine tool, and the through hole of the second semi-finished product is punched once according to the second punching stroke, the second punching frequency and the second punching direction. It's important to understand that after the first semi-finished product is formed using a spherical composite mold, the presence of the filler material inside the holes ensures that the shape of the through holes remains unchanged (or approximately unchanged), their relative positions maintain their original relationships, and their absolute positions shift only with the overall macroscopic deformation of the first semi-finished product without any additional offset. Before forming, the axis of the initial through hole is completely perpendicular to the original plane (the bottom surface of the spinneret semi-finished product). After forming, the original plane conforms to the curvature of the spherical composite mold, transforming into a sphere. Since all normals of the sphere (directions perpendicular to a point of tangency on the sphere) inevitably point to the same center of the sphere, and the filler material firmly supports the hole walls, preventing "asynchronous skew" of the through hole axis, the through hole axis will adjust synchronously with the normal direction of the spherical substrate. Ultimately, the axes of all through holes are aligned with that point on the sphere. The normals coincide and naturally point to the same sphere center, which means that the axes of all through holes will point to the same center (the design center of the spherical composite mold); the second punching stroke during punching is greater than the thickness of the spinneret, and the second punching direction is along the axis of the through hole, from the inlet surface 1 to the outlet surface 2 (since the spherical composite mold is known and the position during forming is known, the second punching direction is also known); for example, the second semi-finished product is installed on an automatic punching machine, requiring the spinneret semi-finished product to be concentric with the automatic punching machine and the bottom surface mounting plane to be consistent. The spinneret semi-finished product is punched according to the second punching stroke of 0.85mm, the second punching frequency of 0.5 seconds / hole, and the second punching direction, wherein the diameter of the punch during this punching is smaller than the diameter of the through hole in the second semi-finished product.

[0045] The second punching direction is different from the first punching direction, and both the first and second punching directions are perpendicular to the bottom surface (spherical surface) of the spinneret.

[0046] S1312, the second semi-finished product after punching is removed from the automatic punching machine and the second semi-finished product undergoes the first post-processing; The first post-processing includes sequential cleaning, grinding, and washing. Specifically, the first cleaning process includes: soaking in an immersion tank, rinsing with warm water, cleaning in an ultrasonic cleaner, and drying in a drying oven. For example, the second semi-finished product is soaked in an immersion tank containing 10% degreasing powder for about 2 hours, then rinsed with 60°C warm water for about 30 minutes, then cleaned in an ultrasonic cleaner with a cleaning power of 1.0Hz for 60 minutes, and finally dried in a dryer with a drying temperature of about 100°C for about 1 hour. Grinding includes: removing the fibers from the product. Surface 2 and the wire-feeding surface 1 are ground to meet the requirements of the drawing. For example, a grinding machine with a speed of 15 r / min is used to grind the cleaned spinneret semi-finished product for 2 hours, wherein the grinding fluid used in the grinding machine contains 8% grinding powder by mass. The cleaning treatment (second time) includes: first high-pressure rinsing, then cleaning in an ultrasonic cleaner and drying in a drying oven. For example, the second semi-finished product is subjected to high-pressure rinsing for 30 minutes, then placed in an ultrasonic cleaner with a cleaning power of 1.0 Hz for 30 minutes, and finally placed in a drying oven with a drying temperature of 100℃ for about 1 hour.

[0047] S1323, The second semi-finished product after the first post-processing is installed on an automatic punching machine, and the through hole of the second semi-finished product is punched once according to the third punching frequency, the preset punching force and the second punching direction. For example, the second semi-finished product is installed on an automatic punching machine. The spinneret semi-finished product is required to be concentric with the automatic punching machine and have the same bottom mounting flatness. The spinneret semi-finished product is punched according to a third punching frequency of 0.5 seconds / hole, a punching force of 25N, and a second punching direction. The diameter of the punch during this punching is equal to the diameter of the through hole in the second semi-finished product (after the previous punching).

[0048] S1324, the second semi-finished product after punching is removed from the automatic punching machine, and the second semi-finished product is subjected to a second post-processing to obtain the spherical spinneret.

[0049] The second post-processing includes sequential cleaning, grinding, and rinsing. Specifically, the first cleaning process includes: soaking in an immersion tank, rinsing with warm water, cleaning in an ultrasonic cleaner, and drying in a drying oven. For example, the second semi-finished product is soaked in an immersion tank containing 15% degreasing powder for about 2 hours, then rinsed with 60°C warm water for about 30 minutes, then cleaned in an ultrasonic cleaner with a cleaning power of 1.0Hz for 65 minutes, and finally dried in a dryer at a drying temperature of about 100°C for about 1 hour. Polishing includes polishing the product's yarn-exit surface 2 and yarn-in surface 1 to meet the drawing requirements. For example, The second semi-finished product after cleaning is polished for 2 hours using a polishing machine with a rotation speed of 15 r / min, so that the roughness of the yarn exit surface 2 and the yarn inlet surface 1 is ≤0.1 μm. The abrasive powder in the polishing slurry used in the polishing machine accounts for 8% of the mass. The cleaning treatment (second time) includes: first high-pressure rinsing, then cleaning in an ultrasonic cleaner and drying in a drying oven. For example: the second semi-finished product is subjected to high-pressure rinsing for 30 minutes, then placed in an ultrasonic cleaner with a cleaning power of 2.0 Hz for 50 minutes, and finally placed in a dryer with a drying temperature of 100℃ for about 1 hour.

[0050] In this embodiment, the punching direction (second punching direction) of each through hole is obtained based on the center of the sphere during pressing, and each through hole is punched at least twice. This can forcibly correct the axial offset and angular deviation during pressing, ensuring that the axis of all through holes strictly points to the center of curvature of the sphere during pressing. This is the core prerequisite for the spinneret to achieve "precise filament convergence" (such as uniform filament distribution in chemical fiber spinning and precise spraying of metal powder in 3D printing). It avoids the problems of "spinning deviation and filament dispersion" caused by axial deviation. At the same time, it can perform "secondary finishing" on the hole wall, scraping off burrs and smoothing out minor scratches, preventing the filament from being caught by burrs and causing "filament breakage" when passing through. By controlling the accuracy of the second punch, the hole diameter can be calibrated to ensure that the hole diameter is uniform throughout the entire process (or meets the design taper, such as a slightly larger entry surface to guide the filament), reducing the filament flow resistance and improving the spinneret stability.

[0051] In one embodiment, step S120, where the first semi-finished product is filled and cured, and then shaped using a spherical composite mold to obtain the second semi-finished product, can be replaced by: After the through-pores of the first semi-finished product are filled and cured with polyurethane microporous elastomer, the first semi-finished product is pressed into shape using a spherical composite mold to obtain the second semi-finished product.

[0052] Among them, polyurethane microporous elastomer is a polyurethane elastic material with a special microporous structure. This material combines the lightweight cushioning of foam plastics with the high strength and wear resistance of elastomers. The cell size is uniformly distributed in the micrometer range, and it has excellent fatigue resistance and compressive stress transmission.

[0053] Specifically, a low-pressure foaming machine can be used for filling. Polyurethane microporous elastomers are made by reacting a mixture of prepolymer and polyol resin, and the two can be mixed in proportion using a low-pressure foaming machine. The uncured reaction liquid is injected into the spinneret orifices at a suitable temperature of 35-60℃. Simultaneously, the spinneret can be preheated to 40-80℃ to aid molding; after curing, the filled elastomer is formed. Alternatively, a pressure injection device can be used for filling: the polyurethane prepolymer component and auxiliary component are thoroughly mixed, and then the liquid mixture is injected into the spinneret orifices using a pressure injection device. Care must be taken to control the injection pressure to prevent excessive pressure from damaging the spinneret or causing uneven material distribution within the spinneret orifices, while insufficient pressure will result in incomplete filling. After filling, pressure must be maintained for a certain period to allow the polyurethane material to cure. Another method is to utilize capillary effect filling: the prepared low-viscosity polyurethane precursor liquid is placed in a container, and the spinneret is inverted so that the spinneret orifices contact the liquid surface. Through capillary action, the liquid slowly seeps into the interior through the tiny spinneret orifices. To optimize the filling effect, the liquid viscosity can be reduced by increasing the temperature or a small auxiliary pressure can be applied to the liquid. However, this method is only suitable for situations where the pore size is extremely small and the filling speed requirement is not high.

[0054] In this embodiment, polyurethane microporous elastomer is used as the pore filler, which can effectively maintain the shape of the pores and reduce the impact of compression molding on the pores.

[0055] In one embodiment, the sheet material is stainless steel or tantalum.

[0056] In this embodiment, the spherical spinneret has a higher compressive strength under the same surface area than the planar spinneret, and when tantalum is used, it has better corrosion resistance than stainless steel. It can be arranged with thousands to tens of thousands of holes under the same working pressure and working surface area.

[0057] Secondly, such as Figure 2 As shown, the present invention also provides a spherical spinneret, which is manufactured by the processing method described in any one of the first aspects.

[0058] The bottom of the spherical spinneret has a spherical structure made of stainless steel or tantalum. The filament exit surface 2 and the filament inlet surface 1 are parallel to each other. The axis of the through holes / spinning orifices on the spherical spinneret is perpendicular to the tangent of its curved surface. Regardless of whether the spinning orifice is located at the center or edge of the sphere, when the spinning solution is extruded from the hole, it can flow out stably in the radial direction perpendicular to the tangent of the sphere. It will not cause "extrusion direction deviation" (i.e., "flow deviation") due to the inclination of the curved surface. The "channel length" of the spinning orifice is consistent throughout the entire spinneret, ensuring that the spinning solution "passes through at a uniform speed" and avoiding pressure fluctuations. In summary, this spherical spinneret reduces flow interference and ensures continuous spinning through "parallel surface + perpendicular hole axis". At the same time, it improves mechanical properties through "uniform extrusion + regular cross section". Ultimately, it can achieve large-scale production with "high capacity, high quality and low loss", which is especially suitable for high-end spinning needs and provides high-quality nascent fiber raw materials for subsequent processes.

[0059] It should be understood that although the steps in the flowcharts of the embodiments described above are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the embodiments described above may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0060] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or system. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or system that includes that element.

[0061] The sequence numbers of the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0062] The above are merely preferred embodiments of the present invention and do not limit the scope of the patent. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of the present invention.

Claims

1. A method of processing a spherical spinneret, characterized by, The processing method of the spherical spinneret includes the following: Obtain a spinneret semi-finished product, and pre-treat the spinneret semi-finished product to obtain a first semi-finished product, wherein the pre-treatment includes one punching. After filling and curing the through holes of the first semi-finished product, the first semi-finished product is pressed and shaped using a spherical composite mold to obtain the second semi-finished product; Remove the filler material from the holes of the second semi-finished product, punch the through holes of the second semi-finished product at least twice, and perform post-processing after each punching to obtain the spherical spinneret.

2. The processing method of the spherical spinneret as described in claim 1, characterized in that, The step of removing the filler material inside the holes of the second semi-finished product includes: After soaking the second semi-finished product in a preset reagent for a preset time, the second semi-finished product is taken out and rinsed.

3. The processing method of the spherical spinneret as described in claim 1, characterized in that, The step of removing the filler material inside the holes of the second semi-finished product includes: After heating the second semi-finished product to a preset temperature, high-pressure airflow is used to blow through the through holes of the second semi-finished product.

4. The processing method of the spherical spinneret as described in claim 1, characterized in that, The step of pre-treating the spinneret semi-finished product to obtain the first semi-finished product includes: The spinneret semi-finished product is installed on an automatic punching machine tool, and punched once according to the first punching frequency, the first punching stroke and the first punching direction to form blind holes. The semi-finished spinneret after punching is removed from the automatic punching machine and subjected to cleaning, grinding and washing processes in sequence to obtain the first semi-finished product, wherein the grinding process processes the blind hole into a through hole.

5. The processing method of the spherical spinneret as described in claim 1, characterized in that, The step of punching the through holes of the second semi-finished product at least twice, and performing post-processing after each punching to obtain the spherical spinneret includes: The second semi-finished product is installed on an automatic punching machine, and the through hole of the second semi-finished product is punched once according to the second punching stroke, the second punching frequency, and the second punching direction. The second semi-finished product after punching is removed from the automatic punching machine and subjected to the first post-processing. The second semi-finished product after the first post-processing is installed on an automatic punching machine, and the through hole of the second semi-finished product is punched once according to the third punching frequency, the preset punching force and the second punching direction. The second semi-finished product after punching is removed from the automatic punching machine and subjected to a second post-processing to obtain the spherical spinneret.

6. The processing method of the spherical spinneret as described in claim 1, characterized in that, The step of filling and curing the through holes of the first semi-finished product, and then using a spherical composite mold to shape the first semi-finished product to obtain the second semi-finished product, can be replaced by: After the through-pores of the first semi-finished product are filled and cured with polyurethane microporous elastomer, the first semi-finished product is pressed into shape using a spherical composite mold to obtain the second semi-finished product.

7. The processing method of the spherical spinneret as described in claim 1, characterized in that, The steps for obtaining the semi-finished spinneret include: Obtain a sheet material, and perform cold rolling on the sheet material to obtain a sheet material of a preset size; According to the preset dimensions, a blanking and stamping compound die is obtained, and the sheet metal of the preset dimensions is stamped to obtain a blank; The blank is shaped using a shaping mold to obtain a spinneret semi-finished product.

8. The processing method of the spherical spinneret as described in claim 7, characterized in that, The sheet material is stainless steel or tantalum.

9. A spherical spinneret, characterized in that, The spherical spinneret is manufactured by the processing method according to any one of claims 1-8.

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