A gradient temperature-controlled water fiber opening device for island-stabilized microfiber substrate fabric

Abstract

This utility model discloses a gradient temperature-controlled water-based fiber opening device for islanded microfiber base fabric, including a control module and a water bath module. The water bath module includes a heating chamber with a heating device at the bottom for temperature regulation. The heating chamber has several perforated flow stabilizers spaced longitudinally to form multiple temperature zones with increasing temperatures from top to bottom. Waterproof ultrasonic transducers are installed at the bottom of the heating chamber and on the perforated flow stabilizers. Each temperature zone includes a winding roller, a pressure roller, and a temperature sensor. The heating chamber has an inlet at the top and a pressing roller outlet at the bottom. The fiber base fabric enters the heating chamber through the inlet, passes through the winding rollers of each temperature zone, and exits the heating chamber through the pressing roller outlet. The water bath module also includes a water receiving tank located outside the pressing roller outlet for receiving extrusion wastewater. This utility model can improve fiber opening uniformity and product quality while optimizing energy utilization efficiency.

Description

Technical Field

[0001] This utility model relates to the technical field of fiber opening devices, and in particular to a gradient temperature-controlled water opening device for islanded microfiber base fabric. Background Technology

[0002] Against the backdrop of escalating global climate change and increasing demands for sustainable resource utilization, the traditional petroleum-based synthetic fiber industry is facing the dual challenges of fossil fuel depletion and environmental pressures. Bio-based island-spinning microfiber technology, by integrating renewable biomass polymers with island-spinning processes, has developed a new generation of environmentally friendly fiber materials, becoming an important pathway for the chemical fiber industry to achieve green transformation.

[0003] However, in current industrial practice, water-soluble microfiber substrates commonly employ alkali-based fiber opening methods, using alkali-soluble COPET as the seaweed component. This seaweed component is dissolved under high-temperature conditions using sodium hydroxide solution. This process not only generates large amounts of alkaline wastewater, causing water pollution and soil acidification, but also easily leads to residual chemicals on the fiber surface, affecting subsequent dyeing and finishing processes and the biosafety of the final product. To overcome these limitations, the industry is actively promoting the use of water-soluble polymers such as polyvinyl alcohol to replace COPET as the seaweed component, using only water as the medium for fiber opening, aiming to eliminate chemical pollution and simplify wastewater treatment. However, during water-based fiber opening, to increase the dissolution rate of the seaweed component, the water temperature often needs to be raised to a relatively high level. This single high-temperature operation mode has led to multiple technical challenges: continuous high temperatures significantly increase equipment energy consumption and production costs; more importantly, in the initial stage of fiber opening, excessively high water temperatures cause the marine components to swell violently, resulting in the fibers sticking together and damaging the structural integrity of the fiber opening channels, which in turn hinders the uniform separation of microfibers. Ultimately, this results in quality defects in the fiber base fabric, such as uneven strength distribution and increased surface hairs, which seriously restricts the large-scale production and application of bio-based island-fixed microfibers. Utility Model Content

[0004] Based on this, the present invention proposes a gradient temperature-controlled water fiber opening device for island-fixed microfiber base fabric, which has the advantages of effectively avoiding the adhesion phenomenon of fiber base fabric caused by temperature change during the fiber opening process, improving fiber opening uniformity and product quality, and optimizing energy utilization efficiency.

[0005] To achieve the above objectives, the present invention adopts the following technical solution.

[0006] A gradient temperature-controlled water-based fiber opening device for island-fixed microfiber base fabric includes a control module and a water bath module. The water bath module includes a heating chamber with a heating device at the bottom for temperature regulation. The heating chamber is longitudinally spaced with several perforated flow stabilizers to form multiple temperature zones with increasing temperature from top to bottom. Waterproof ultrasonic transducers are respectively installed at the bottom of the heating chamber and on the perforated flow stabilizers. A winding roller, a pressure roller, and a temperature sensor are installed in each temperature zone. A feed inlet is provided at the top of the heating chamber, and a pressing roller outlet is provided at the bottom of the heating chamber. The fiber base fabric enters the heating chamber from the feed inlet, passes around the winding rollers of each temperature zone, and leaves the heating chamber from the pressing roller outlet. The water bath module also includes a water receiving tank located outside the pressing roller outlet for receiving extrusion wastewater.

[0007] By utilizing the principle of natural convection of hot fluids and combining it with the flow-suppressing effect of porous flow-stabilizing baffles, a stable vertical temperature gradient was successfully formed within a single cavity, eliminating the need for multiple independent heaters and significantly reducing energy consumption. This effectively avoids the increased energy consumption caused by a single high-temperature environment and prevents rapid swelling of the marine components and fiber adhesion caused by excessively high temperatures in the early stages of fiber opening, thereby significantly improving the quality of the island-fixed microfiber base fabric. The ultrasonic device and multiple pressure rollers work together to promote water penetration into the microfiber base fabric and the discharge of dissolved products through ultrasonic waves and mechanical decompression, effectively solving the problem of insufficient internal fiber opening caused by gelation of dissolved marine components, achieving uniform and sufficient fiber opening from the inside out. The gradient temperature control design, employing a low-temperature followed by a high-temperature approach, reduces the sensitivity of fibers to high-temperature water in the early stages of fiber opening, avoiding fiber adhesion caused by rapid expansion of the marine components due to water absorption, which helps maintain the fiber opening channels and improves the quality of the microfiber base fabric.

[0008] Furthermore, this application proposes that the control module includes a control panel, a heating device, and a pump and valve system. The water bath module is located at the top of the control module, and the heating device is located in the middle of the control module and transfers the generated heat to the water bath module. The pump and valve system is located at the bottom of the device and can control water replenishment and periodically drain wastewater to maintain stable water levels and clean water quality in the working area.

[0009] Furthermore, this application proposes that each temperature zone is equipped with at least two pressure rollers, and each temperature zone's wrapping roller includes at least two guide rollers, with the pressure rollers and guide rollers arranged correspondingly. By stacking the number of guide rollers, the number of folded layers of the microfiber base fabric can be adjusted, which is beneficial to improving space utilization. The ultrasonic treatment and the mechanical action of the pressure rollers can remove the dissolved polymers in the microfiber base fabric to the maximum extent, achieving a high dissolution rate of marine components.

[0010] Furthermore, this application proposes that the heating chamber is provided with a first temperature zone, a second temperature zone, and a third temperature zone distributed sequentially from bottom to top along its longitudinal direction. The heating temperature range of the first temperature zone is 80-100 ℃, the heating temperature range of the second temperature zone is 60-80 ℃, and the heating temperature range of the third temperature zone is 40-60 ℃. After the island-shaped microfiber base fabric enters the container, it passes through three different temperature zones from low to high in sequence. Ultrasonic treatment combined with pressure roller pressing is beneficial to maintaining the open fiber channels. The dissolved marine components are extruded with the aqueous solution, which can improve the dissolution rate of marine components in the base fabric and reduce the residue of water-soluble polymers.

[0011] Furthermore, this application proposes that a submersible liquid level sensor be installed at the top of the heating chamber to monitor the liquid level height within the heating chamber. The submersible liquid level sensor enables liquid level control; when the water level falls below a set lower limit, the water supply valve automatically opens; when the water level reaches the upper limit, it automatically closes.

[0012] Furthermore, this application proposes that the feed inlet and the extrusion roller outlet are located at two diagonal positions within the respective heating chambers. After entering the heating chamber, the fiber base fabric first passes through a low-temperature zone, and then gradually descends along a diagonal path through a medium-temperature zone and a high-temperature zone, thereby achieving the gradual dissolution of the marine components. This path arrangement ensures that the fiber base fabric is within a suitable temperature range in the initial stage of fiber opening, effectively suppressing the rapid swelling of the marine components and fiber adhesion, while maintaining the structural stability of the fiber opening channels.

[0013] Furthermore, this application also proposes that a winding machine for winding the fiber base fabric is provided outside the extrusion roller outlet of the heating chamber, and a lifting roller is provided between the extrusion roller outlet and the winding machine. The horizontal height of the lifting roller is higher than the height of the extrusion roller outlet to reduce the water carried out by the fiber base fabric from the extrusion roller outlet.

[0014] Furthermore, this application proposes that the heating cavity is a vertical cylindrical container with a height-to-diameter ratio greater than 3:1. The axisymmetric characteristics of the vertical cylindrical container allow the heat generated by the heating device to be uniformly transferred longitudinally, avoiding localized overheating caused by edge effects in traditional asymmetric cavities. Simultaneously, the height-to-diameter ratio greater than 3:1 significantly increases the ratio of height to diameter, strengthening the formation mechanism of the longitudinal temperature gradient, reducing interference from radial heat exchange, ensuring that the porous flow stabilizer plate can stably maintain a temperature increase trend from top to bottom, and guiding the water flow smoothly along the axial direction. This avoids fiber adhesion problems caused by water vortices or short circuits when the fiber base fabric moves between the wrapping roller and the pressure roller.

[0015] Furthermore, this application proposes that a waterproof ultrasonic transducer is positioned at the center of the bottom of the temperature zone, and a rectangular groove is provided on one side of the porous flow stabilizer for the fiber base fabric to pass through. This ensures stable ultrasonic radiation in both the transverse and longitudinal directions, effectively suppressing the rapid swelling of marine components caused by uneven energy distribution. Simultaneously, the rectangular groove of the porous flow stabilizer serves as the sole passageway, preventing direct contact between the fiber base fabric and the porous structure of the plate, reducing water flow turbulence and resistance to the base fabric's movement, thereby synergistically maintaining the continuous formation and stability of the open fiber channels.

[0016] Furthermore, this application proposes that the sides of the heating chamber be covered with heat-insulating baffles, and the top of the heating chamber be equipped with a heat-insulating cover. This reduces heat loss, lowers equipment operating energy consumption, and ensures the stability of the temperature zone, thereby improving the efficiency of the fiber opening process and product quality.

[0017] Compared with the prior art, this utility model has the following advantages: (1) By utilizing the principle of natural convection of hot fluid, combined with the container design with a specific height-to-diameter ratio and the flow suppression effect of porous flow stabilizing baffles, a stable vertical temperature gradient was successfully formed in a single cavity, eliminating the need for multiple independent heaters and significantly reducing energy consumption. (2) The second working unit is equipped with an ultrasonic device and multiple pressure rollers. Through ultrasonic waves and mechanical decompression, water penetration into the interior of the ultrafine fiber base fabric and the discharge of dissolved products are promoted. This effectively solves the problem of insufficient internal fiber opening caused by the gelation of marine component dissolved products, and achieves uniform and sufficient fiber opening from the inside to the outside. (3) This device adopts a gradient temperature control design of low temperature first and high temperature later, which reduces the sensitivity of the fiber to high temperature water in the early stage of fiber opening, avoids the fiber sticking problem caused by rapid expansion of the sea component after absorbing water, and helps to maintain the fiber opening channel and improve the quality of the microfiber base fabric. (4) This device adopts an integrated structure with clear functional zoning, no complex moving parts, simplified process settings, and small footprint, which is conducive to improving space utilization. Attached Figure Description

[0018] Figure 1 This is a cross-sectional view of the gradient temperature-controlled water fiber-opening device used for island-fixed microfiber base fabric in this utility model; Figure 2 This is a front view of the gradient temperature-controlled water fiber-opening device for island-fixed microfiber base fabric in this utility model; Figure 3 These are the top and front views of the heating device in this utility model; Figure 4 This is a top view of the porous flow-stabilizing baffle in this utility model, with a waterproof ultrasonic transducer in the middle.

[0019] In the diagram: Control module 1, Water bath module 2, Insulation partition 3, Control panel 4, Heating device 5, Waterproof ultrasonic transducer I 6-1, Waterproof ultrasonic transducer II 6-2, Waterproof ultrasonic transducer III 6-3, Feed inlet 7, Porous flow stabilizer I 8-1, Porous flow stabilizer II 8-2, Pressure roller I 9-1, Pressure roller II 9-2, Pressure roller III 9-3, Pressure roller IV 9-4, Pressure roller V 9-5, Pressure roller VI 9-6, Inlet guide roller 10, Guide roller I 11-1, Guide roller II 11-2, Guide roller III 11-3, Guide roller IV 11-4, Submersible liquid level sensor 12, Heat insulation cover plate 13, Temperature sensor I 14-1, Temperature sensor II 14-2, Temperature sensor III 14-3, Extrusion roller outlet 15, Winding machine 16, Pump and valve device 17, Water receiving tank 18, First temperature zone 19, Second temperature zone 20, Third temperature zone 21, Lifting roller 22. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0021] Example like Figures 1 to 4 As shown, this application proposes a gradient temperature-controlled water fiber opening device for island-fixed microfiber base fabric, including a control module 1 and a water bath module 2. The water bath module 2 includes a heating chamber, and a heating device 5 is provided at the bottom of the heating chamber to achieve temperature regulation. Several porous flow stabilizers are arranged longitudinally in the heating chamber to form multiple temperature zones with increasing temperature from top to bottom. Waterproof ultrasonic transducers are respectively provided at the bottom of the heating chamber and on the porous flow stabilizers. A winding roller, a pressure roller and a temperature sensor are provided in the temperature zone. A feed inlet is provided at the top of the heating chamber and a pressing roller outlet 15 is provided at the bottom of the heating chamber. The fiber base fabric enters the heating chamber from the feed inlet and passes around the winding roller of each temperature zone before leaving the heating chamber from the pressing roller outlet 15. The water bath module 2 also includes a water receiving tank 18 located outside the pressing roller outlet 15 for receiving extrusion wastewater.

[0022] In the water-splitting process of bio-based island-fixed microfibers, when water-soluble polymers are used as the marine component, a relatively high water temperature is usually required to improve the dissolution efficiency of the marine component. However, excessively high water temperatures cause the marine component to swell rapidly in the initial stage of fiber splitting, leading to fiber adhesion and disrupting the stability of the fiber splitting channels. This, in turn, affects the uniformity and structural integrity of the island-fixed microfiber substrate. Simultaneously, continuous high-temperature operation increases energy consumption, reduces the economic efficiency of the process, and weakens the ability to maintain the splitting channels, making it difficult for the substrate quality to meet industrial application requirements.

[0023] For example, in the water-opening process of the Dingdao microfiber production line, the heating chamber is set to a high temperature to accelerate the dissolution of the marine component. After the fiber base fabric enters the heating chamber, the marine component rapidly absorbs water and swells, causing adjacent fibers to adhere to each other and form local agglomerations, compressing or closing the opening channels. Temperature sensors detect uneven temperature distribution, resulting in irregular adhesion points on the surface of the fiber base fabric and deviations in the winding path. The final product has uneven strength distribution and surface structural defects, requiring additional processing to meet the requirements of subsequent processes.

[0024] If the above problems are not resolved, the rapid swelling of the marine components and fiber adhesion caused by high temperatures will lead to the continued occurrence of incomplete fiber opening in the island-fixed microfiber base fabric, increasing structural defects and significantly affecting the mechanical properties and surface quality of the base fabric. Increased energy consumption will raise production costs, and reduced process stability may cause equipment malfunctions, hindering the reliable implementation of water-based fiber opening technology in large-scale production.

[0025] In this embodiment, the porous flow stabilizer plate refers to a structure used to divide the space within the heating chamber and form a stable water flow channel. In practical applications, it can be made of metal mesh or porous ceramic materials, such as 304 stainless steel mesh or porous alumina plate, mainly to achieve uniform water flow distribution and stable temperature maintenance. The waterproof ultrasonic transducer refers to a device capable of generating ultrasonic vibrations in an aquatic environment. It can be implemented using piezoelectric ceramic transducers or magnetostrictive transducers, such as lead zirconate titanate piezoelectric ceramic transducers or iron-nickel alloy magnetostrictive transducers, mainly to assist in the dissolution of marine components by ultrasonic waves. Furthermore, multiple temperature zones refer to areas with different temperature levels distributed longitudinally within the heating chamber. This can be achieved by adjusting the power distribution of the heating device 5 or by setting up an independent temperature control system, such as using a frequency converter heating controller or zoned temperature sensor feedback control, mainly to achieve a temperature gradient change during fiber opening. Specifically, after the fiber base fabric enters the heating chamber from the feed inlet, it passes through each temperature zone sequentially, utilizing the longitudinally increasing temperature from top to bottom during the initial fiber opening stage. Therefore, this application, by setting up a multi-temperature zone structure with increasing temperature from top to bottom, avoids a single high-temperature environment during the fiber opening process of the fiber base fabric, effectively maintaining the stability of the fiber opening channels, thereby solving the problems of increased energy consumption and fiber adhesion caused by high temperature during water fiber opening. As a preferred embodiment, the configuration of the winding roller and pressure roller within the temperature zone guides the stable operation of the fiber base fabric and ensures sufficient contact with water, while temperature sensors provide real-time data feedback to support accurate temperature regulation.

[0026] This gradient temperature-controlled water-based fiber opening device achieves precise control over the fiber opening process on the island-fixed ultrafine fiber substrate through the coordinated action of control module 1 and water bath module 2. A heating device 5 is installed at the bottom of the heating chamber of water bath module 2 to regulate the internal temperature of the chamber. Several porous flow stabilizers are longitudinally spaced within the heating chamber, forming multiple temperature zones with increasing temperatures from top to bottom. The porous flow stabilizers can specifically be stainless steel mesh structures. The fiber substrate enters through the feed inlet at the top of the heating chamber, initially initiating the dissolution process of the marine components in the low-temperature zone at the top. Subsequently, the fiber substrate moves downwards, passing through the medium-temperature zone and the high-temperature zone in sequence. This gradually increasing temperature environment effectively maintains the stability of the fiber opening channels. Furthermore, waterproof ultrasonic transducers, such as piezoelectric ceramic ultrasonic transducers, are respectively installed at the bottom of the heating chamber and on the porous flow stabilizers. These transducers assist in the dissolution of the marine components through ultrasonic vibration, reducing dependence on continuous high temperatures. Within the heating zone, a winding roller guides the fiber base fabric along a stable path, while a pressure roller ensures sufficient contact between the fibers and water for uniform fiber opening. A temperature sensor monitors the temperature within the heating zone in real time and feeds it back to the control module 1 for dynamic adjustment. The fiber base fabric ultimately exits from the extrusion roller outlet 15 at the bottom of the heating chamber, and the extruded wastewater is promptly collected by an external water collection tank 18.

[0027] In this embodiment, the control module 1 includes a control panel 4, a heating device 5, and a pump and valve device 17. The water bath module 2 is located on top of the control module 1, and the heating device 5 is located in the middle of the control module 1 and transfers the generated heat to the water bath module 2. In practical applications, the control panel 4 refers to the user interface, which can be implemented using a touch screen or a physical button panel, with the purpose of providing monitoring and adjustment functions for system parameters; the heating device 5 refers to the heat source generating device, which can be implemented using an electric heater or a heat exchanger, with the purpose of providing the required heat to the water bath module 2; the pump and valve device 17 refers to the fluid control unit, which can be implemented using a combination of a water pump and a solenoid valve, with the purpose of adjusting the water flow speed and direction in the water bath module 2; the water bath module 2 being located on top of the control module 1 means that the water bath module 2 is located above the control module 1, which can be implemented by direct installation or bracket fixation, with the purpose of utilizing the physical property of hot air rising naturally to optimize heat transfer efficiency; the heating device 5 being located in the middle of the control module 1 means that the heating device 5 is located in the central area inside the control module 1, which can be implemented by embedded installation, with the purpose of shortening the heat transmission path and reducing heat loss. By integrating the control module 1 with the control panel 4, heating device 5, and pump and valve device 17, centralized management of operation monitoring, heat source supply, and fluid regulation is achieved, avoiding signal delay and energy loss caused by decentralized design. The water bath module 2 is located on top of the control module 1, enabling efficient heat transfer in the vertical direction, reducing reliance on additional power equipment, and meeting the bottom-to-top temperature distribution requirements in gradient temperature control. The heating device 5 is positioned in the middle of the control module 1 and directly transfers heat to the water bath module 2, significantly shortening the heat transfer path and avoiding heat loss caused by detours or long-distance diffusion, ensuring accurate and rapid heat input to the water bath module 2, thereby enhancing the stability and response speed of the temperature zone.

[0028] As a preferred embodiment, the solution of this application is specifically implemented as follows: the control panel 4 adopts an industrial-grade touch screen interface, the pump and valve device 17 includes a centrifugal pump and a proportional control valve, the water bath module 2 is fixed to the top of the control module 1 through a flange connector, and the heating device 5 is embedded in the middle of the control module 1.

[0029] This application further proposes that each temperature zone has at least two pressure rollers, and each temperature zone's wrapping roller includes at least two guide rollers, with the pressure rollers and guide rollers arranged correspondingly. The pressure roller refers to a roller used to apply pressure to the fiber base fabric, which can be a metal roller or a rubber-coated roller; the guide roller can be understood as a roller used to change the direction of travel of the fiber base fabric, which can be a guide roller made of stainless steel; the corresponding arrangement specifically refers to the spatial cooperation between the pressure rollers and the guide rollers, which can be achieved by placing the pressure roller on the inlet or outlet side of the guide roller.

[0030] An immersion-type liquid level sensor 12 is installed at the top of the heating chamber to monitor the liquid level. By fixing the sensor 12 to the inner wall of the top of the heating chamber, its probe directly contacts the liquid surface and continuously monitors the liquid level. The control system automatically triggers water replenishment or drainage operations based on the real-time data from the sensor to adjust the liquid level, ensuring it remains stable within a reasonable range. Since water is the heat transfer medium, precise liquid level control effectively ensures the uniformity of heat distribution in each temperature zone, avoiding problems such as insufficient fiber opening due to partial dehydration of the fiber substrate due to excessively low liquid levels, or water overflow and temperature zone confusion due to excessively high liquid levels. Simultaneously, this location avoids water flow interference from the bottom heating device 5 and the porous flow stabilizer, ensuring stable sensor operation without affecting the movement path of the fiber substrate. In practical applications, the immersion-type liquid level sensor 12 refers to a sensing device that can be directly immersed in a liquid environment for continuous liquid level measurement. It can be implemented using capacitive, ultrasonic, or float-type liquid level sensors, aiming to provide high-precision real-time liquid level data, thereby laying the foundation for maintaining the stability of the water bath environment. As a preferred embodiment, the solution of this application is specifically implemented as follows: the submersible liquid level sensor 12 can be specifically a capacitive liquid level sensor, whose probe is fixed to the inner wall of the top of the heating chamber through a high-temperature resistant sealing structure, and is electrically connected to the control module 1 to reliably acquire liquid level signals in a high-temperature water bath environment.

[0031] This application further proposes that the feed inlet and the extrusion roller outlet 15 are located at two diagonal positions within the respective heating chambers. For example... Figure 1 As shown, the feed inlet is located on the left side of the top end face of the heating chamber, and the extrusion roller outlet 15 is located on the right side of the bottom of the heating chamber. This allows the flow path of the fiber base fabric to be rationally planned according to the longitudinal temperature gradient.

[0032] To prevent water carried by the fiber base fabric from dripping and spreading during movement due to gravity or vibration, thus avoiding increased wastewater treatment volume, water waste, and potential environmental pollution, this application further proposes a winding machine 16 for winding the fiber base fabric located outside the extrusion roller outlet 15 of the heating chamber. A lifting roller 22 is provided between the extrusion roller outlet 15 and the winding machine 16, with the horizontal height of the lifting roller 22 being higher than the height of the extrusion roller outlet 15 to reduce the water carried out by the fiber base fabric from the extrusion roller outlet 15.

[0033] The winding machine 16 refers to the equipment used to wind the processed fiber base fabric. It can be implemented using an electric winding device or a pneumatic winding mechanism, with the aim of efficiently collecting the fiber base fabric and maintaining a continuous production process. The lifting roller 22 is a support guide roller used to change the travel path of the fiber base fabric. It can be implemented using a smooth-surfaced metal roller or ceramic roller, with the aim of promoting the natural separation of adhering water through height difference. Specifically, the lifting roller 22 is a stainless steel roller, mounted on an adjustable-height bracket, located in the transmission path between the extrusion roller outlet 15 and the winding machine 16. After the fiber base fabric is drawn from the extrusion roller outlet 15, it first passes upwards around the top of the lifting roller 22, and then downwards into the winding area of ​​the winding machine 16. In this way, during the lifting process, the water adhering to the surface of the fabric continues to drip off due to gravity, while the smooth surface of the lifting roller 22 reduces water residue, ensuring that the fiber base fabric enters the winding stage with a low moisture content.

[0034] If the heating chamber shape is not properly designed, it can lead to uneven temperature distribution and turbulent water flow, which in turn can cause rapid swelling of marine components and fiber adhesion, affecting the fiber opening quality of the island-fixed microfiber base fabric. Therefore, this application further proposes that the heating chamber be a vertical cylindrical container with a height-to-diameter ratio greater than 3:1. In practical applications, a vertical cylindrical container refers to a vertically placed cylindrical structure, which can be made of stainless steel or heat-resistant engineering plastics to ensure structural stability and corrosion resistance in a high-temperature water bath environment. Its purpose is to provide an axisymmetric geometry to promote uniform heat distribution along the longitudinal direction. As a preferred embodiment, the solution of this application is specifically implemented as follows: the heating chamber is a vertical cylindrical container made of stainless steel with a height-to-diameter ratio set to 3.5:1 to ensure the stability of water flow and the uniformity of temperature distribution during gradient temperature control.

[0035] The waterproof ultrasonic transducer used in this embodiment is positioned at the center of the bottom of the temperature zone, and a rectangular groove on one side of the porous flow stabilizer plate allows the fiber base fabric to pass through. The waterproof ultrasonic transducer is an ultrasonic wave generator capable of stable operation in an aquatic environment. It can be implemented using a transducer made of piezoelectric ceramic or magnetostrictive material, aiming to uniformly radiate ultrasonic energy from the geometric center and avoid excessive local energy intensity or attenuation. The porous flow stabilizer plate can be understood as a plate-like structure used to regulate water flow. It can be implemented using a perforated plate made of stainless steel or engineering plastic, aiming to reduce water flow disturbance and maintain laminar flow. The rectangular groove on one side serves as a dedicated channel to guide the fiber base fabric smoothly through. The waterproof ultrasonic transducer uses a cylindrical piezoelectric ceramic structure and is firmly installed at the center of the bottom of the temperature zone. The width of the rectangular groove on the porous flow stabilizer plate is slightly larger than the thickness of the fiber base fabric, and the groove edges are chamfered to reduce frictional resistance, ensuring that the base fabric moves smoothly only through this groove under the guidance of the wrapping roller.

[0036] The heating cavity is covered with a thermal insulation partition 3 on its sides and a thermal insulation cover 13 on its top. Specifically, the thermal insulation partition 3 is a heat-barrier material layer, which can be made of aluminum silicate fiberboard, rock wool board or polyurethane foam board, with the purpose of reducing heat loss from the sides of the heating cavity; the thermal insulation cover 13 can be understood as a top thermal barrier structure, which can be made of double-layer metal plate sandwich thermal insulation material or integral ceramic fiber board, with the purpose of blocking the heat loss path from the top of the heating cavity.

[0037] In a preferred embodiment, the heating chamber is provided with a first temperature zone 19, a second temperature zone 20 and a third temperature zone 21 arranged sequentially from bottom to top along its longitudinal direction. The heating temperature range of the first temperature zone 19 is 80-100 ℃, the heating temperature range of the second temperature zone 20 is 60-80 ℃, and the heating temperature range of the third temperature zone 21 is 40-60 ℃.

[0038] The fiber base fabric enters the water bath module 2 through the feed inlet 7 located at the inlet of the water bath module 2 and the inlet guide roller 10. Within the third temperature zone 21 of the water bath module 2, pressure rollers VI 9-6, V 9-5, guide roller IV 11-4, and a porous flow stabilizer II 8-2 are sequentially arranged along the conveying direction of the fiber base fabric. Pressure rollers VI 9-6 and V 9-5 are located in the central area of ​​the third temperature zone 21 and are used to compress the swollen fiber base fabric. Guide roller IV 11-4 is located to the upper right of the porous flow stabilizer II 8-2 and is used to convey the fiber base fabric to the second temperature zone 20.

[0039] In the second temperature zone 20 and the first temperature zone 19 of the water bath module 2, there are sequentially arranged a steering roller III 11-3, a pressure roller IV 9-4, a pressure roller III 9-3, a steering roller II 11-2, a porous flow stabilizer I 8-1, a steering roller I 11-1, a pressure roller II 9-2, a pressure roller I 9-1, and an extrusion roller outlet 15. The fiber base fabric enters the second temperature zone 20 through the steering roller III 11-3. The pressure rollers IV 9-4 and III 9-3 are located on both sides of the container and are used to assist the dissolution and fiber opening of the marine components through multiple mechanical extrusion actions. The steering roller II 11-2 is located above the porous flow stabilizer I 8-1 and is symmetrically distributed with the steering roller I 11-1 located below the porous flow stabilizer I 8-1. It is used to directionally convey the fiber base fabric to the first temperature zone 19. The first temperature zone 19 also includes pressure rollers II 9-2 and I 9-1. The fiber base fabric is directionally conveyed along pressure rollers II 9-2 located on the upper right side of the middle and pressure rollers I 9-1 located on the lower left side of the middle until it leaves the water bath module 2 at the extrusion roller outlet 15.

[0040] like Figure 3As shown, the heating device 5 in control module 1 is assembled from flange-type tubular electric heaters. The total power is controllable by the number of units installed. The flange installation facilitates future maintenance and replacement. The porous flow stabilizer I 8-1 and porous flow stabilizer II 8-2 have an opening rate of 25%-30% to suppress vertical convection and maintain stable temperature in the temperature zone. A rectangular groove is provided on one side of each plate to facilitate the transport of the fiber base fabric. Waterproof ultrasonic transducers II 6-2 and III 6-3 are connected to the central areas of porous flow stabilizer I 8-1 and porous flow stabilizer II 8-2, respectively, for ultrasonic-assisted fiber opening, preventing internal processing dead zones and achieving uniform fiber opening from the surface inwards.

[0041] The control panel 4 is interconnected with the heating device 5 and the pump and valve device 17 for signal processing and issuing commands.

[0042] In addition, temperature sensors I14-1, II14-2, and III14-3, which are located inside the water bath module 2, are electrically connected to the control panel 4 located in the control module 1 to monitor the temperature of each temperature zone.

[0043] The method of using this utility model is as follows: the fiber base fabric enters the water bath module 2 through the feed port 7 located at the conveying inlet of the water bath module 2, and is conveyed from top to bottom by several guide rollers arranged along the height direction. Finally, it is conveyed out of the working area through the extrusion roller outlet 15 and wound up by the winding machine 16. During this process, the heating device 5 of the control module 1 provides a heat source, and a stable vertical temperature gradient is achieved in the container by utilizing the principle of natural convection of hot fluid. The control panel 4 is electrically connected to several sensors installed in the water bath module 2, realizing precise control and rapid stabilization of the temperature in each temperature zone. In addition, the water bath module 2 uses an ultrasonic device and pressure rollers to achieve uniform fiber opening of the fiber base fabric from the surface to the inside.

[0044] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A gradient temperature control water opening device for islanding superfine fiber base cloth, characterized in that, The system includes a control module and a water bath module. The water bath module includes a heating chamber with a heating device at the bottom for temperature regulation. The heating chamber is longitudinally spaced with several perforated flow stabilizers to form multiple temperature zones with increasing temperature from top to bottom. Waterproof ultrasonic transducers are installed at the bottom of the heating chamber and on the perforated flow stabilizers. A wrapping roller, a pressure roller, and a temperature sensor are installed in each temperature zone. A feed inlet is located at the top of the heating chamber, and a pressing roller outlet is located at the bottom of the heating chamber. The fiber base fabric enters the heating chamber from the feed inlet, passes around the wrapping rollers in each temperature zone, and exits the heating chamber from the pressing roller outlet. The water bath module also includes a water receiving tank located outside the pressing roller outlet for receiving extrusion wastewater.

2. The gradient temperature control water opening device for islanding superfine fiber base cloth according to claim 1, characterized in that, The control module includes a control panel, a heating device, and a pump and valve device. The water bath module is located on top of the control module, and the heating device is located in the middle of the control module and transfers the generated heat to the water bath module.

3. The gradient temperature control water opening device for islanding superfine fiber base cloth according to claim 1, characterized in that, Each temperature zone is provided with at least two pressure rollers, and each temperature zone's wrapping roller includes at least two guide rollers, with the pressure rollers and guide rollers being arranged accordingly.

4. The gradient temperature control water opening device for islanding superfine fiber base cloth according to claim 1, characterized in that, The heating chamber is provided with a first temperature zone, a second temperature zone, and a third temperature zone arranged longitudinally from bottom to top. The heating temperature range of the first temperature zone is 80-100 ℃, the heating temperature range of the second temperature zone is 60-80 ℃, and the heating temperature range of the third temperature zone is 40-60 ℃.

5. The gradient temperature controlled hydro-fibrillation device for islanding the superfine fiber-based fabric according to claim 1, characterized in that, An immersion-type liquid level sensor is installed at the top of the heating chamber to monitor the liquid level height in the heating chamber.

6. The gradient temperature controlled hydro-fibrillation device for islanding the superfine fiber-based fabric according to claim 1, characterized in that, The feed inlet and the extrusion roller outlet are located at two opposite corners of the heating chamber.

7. The gradient temperature controlled hydro-fibrillation device for islanding the superfine fiber-based fabric according to claim 1, characterized in that, A winding machine for winding the fiber base fabric is provided outside the extrusion outlet of the extrusion roller in the heating chamber. A lifting roller is provided between the extrusion outlet of the extrusion roller and the winding machine. The horizontal height of the lifting roller is higher than the height of the extrusion outlet of the extrusion roller to reduce the water carried out by the fiber base fabric from the extrusion outlet of the extrusion roller.

8. The gradient temperature controlled hydro-fibrillation device for islanding the superfine fiber-based fabric according to claim 1, characterized in that, The heating cavity is a vertical cylindrical container with a height-to-diameter ratio greater than 3:

1.

9. The gradient temperature controlled hydro-fibrillation device for islanding the superfine fiber-based fabric according to claim 1, characterized in that, The waterproof ultrasonic transducer is located at the center of the bottom of the temperature zone, and a rectangular groove for the fiber base cloth to pass through is provided on one side of the porous flow stabilizer plate.

10. A gradient temperature-controlled water-based fiber-opening device for island-stabilized microfiber base fabric according to any one of claims 1 to 9, characterized in that, The heating cavity is covered with a heat-insulating partition on its sides and a heat-insulating cover on its top.

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