A constant temperature and constant net air treatment system for chemical fiber melt spinning process

Abstract

The utility model discloses a kind of constant temperature constant net air treatment systems for chemical fiber melt spinning process, including unit shell, three-layer gradient filtration system, temperature initial regulation unit and constant temperature regulation unit. Through multistage filtration and dynamic temperature regulation, realize the high cleanliness and accurate constant temperature of air in spinning duct, in addition to air velocity sensor and the frequency conversion fan and flow equalizing plate linked therewith, can ensure that airflow distribution is uniform in duct, significantly improve tow cooling uniformity and product quality consistency. System uses existing steam and circulating water system of factory, energy-efficient, and is equipped with maintenance window, convenient filter screen replacement.

Description

Technical Field

[0001] This utility model relates to the field of chemical fiber manufacturing equipment technology, specifically to a constant temperature and clean air treatment system for chemical fiber melt spinning process. Background Technology

[0002] In chemical fiber production, especially in melt spinning, the molten filaments extruded from the spinneret are extremely sensitive to the temperature and cleanliness of the surrounding environment during cooling and solidification. The temperature stability of the air within the spinning tunnel directly determines the fiber's fineness, strength, elongation, and other physical properties. Furthermore, impurities in the air such as dust, oil mist, water vapor, and microorganisms can easily lead to spinneret blockage, fiber breakage, fuzzing, surface defects, and uneven strength, severely impacting fiber quality and production efficiency. To ensure uniform cooling of the filaments and prevent problems such as uneven fiber diameter, uneven strength, and abnormal shrinkage caused by temperature fluctuations, the spinning tunnel typically requires precise control of temperature and airflow.

[0003] Currently, conventional air conditioning or air purification equipment often only has a single temperature regulation or simple filtration function, which cannot meet the dual requirements of high cleanliness and precise constant temperature at the same time. Moreover, the air supply system lacks targeted design, making it difficult to deliver the treated air evenly and stably to the spinneret microenvironment, resulting in defects such as large temperature fluctuations, turbulent airflow, and insufficient cleanliness.

[0004] Therefore, there is an urgent need for an air handling system specifically designed for chemical fiber production, integrating high-efficiency filtration, precise temperature control, and stable airflow delivery to improve the air environment quality during the spinning process and ensure the stability and consistency of fiber quality. Utility Model Content

[0005] The purpose of this invention is to overcome the defects in the existing technology and provide a constant temperature and clean air treatment system for the melt spinning process of chemical fibers.

[0006] To achieve the above objectives, the technical solution of this utility model is to design a constant temperature and clean air treatment system for the melt spinning process of chemical fibers, including a unit housing. An air inlet is provided on one side of the unit housing, and an external filter screen is provided at the air inlet to prevent debris from entering the housing. The unit housing is equipped with a three-layer filtration system, namely a primary filter layer, a medium-efficiency filter layer, and a high-efficiency filter layer. The external filter screen is preferably a stainless steel wire mesh, and its main function is to intercept large-sized debris such as leaves and flying insects, preventing them from entering the housing and damaging subsequent precision filtration components or the fan. The primary filter layer filters coarse particles (such as dust and pollen) with a particle size ≥5μm, typically using G4 grade nonwoven fabric or metal mesh; the medium-efficiency filter layer filters fine particles (such as fiber debris) with a particle size ≥1μm, typically using F7 grade glass fiber or synthetic fiber filter media; the high-efficiency filter layer filters particulates (such as ultrafine dust and aerosols) with a particle size ≥0.3μm, typically using H13 grade HEPA filter paper, ensuring that the air entering the spinning tunnel meets the "Class 100 / Class 1000 cleanliness" standard.

[0007] The system also includes a temperature pre-regulation unit. This unit comprises a first temperature sensor located within the unit housing to monitor the internal air temperature, and heating and cooling pipes located on one side of the housing. The heating pipe contains a heating fan and a heating device, and the cooling pipe contains a cooling fan and a cooling device. The heating and cooling pipes converge at their ends into a buffer pipe, which leads to the spinning tunnel. The first temperature sensor monitors the temperature of the filtered air in real time and transmits the signal to the controller. The temperature pre-regulation unit compares the ambient temperature with a set temperature to determine whether the ambient air needs to be heated or cooled, thereby selecting either the heating or cooling pipe. The air temperature after processing by this unit is slightly lower than the required temperature.

[0008] The system also includes a temperature control unit, which comprises a second temperature sensor, a temperature control device, and a variable frequency fan located at the end of the buffer pipe near the spinning tunnel. A wind speed sensor is installed at the connection between the buffer pipe and the spinning tunnel. The first temperature sensor, the second temperature sensor, the heating fan, the cooling fan, the variable frequency fan, and the wind speed sensor are electrically connected to the controller. The second temperature sensor monitors the air temperature entering the spinning tunnel in real time, providing a final temperature feedback signal. The temperature control unit maintains the final air temperature, after processing by the initial temperature control unit and influenced by the buffer pipe, within a set range, ensuring a constant air temperature entering the spinning tunnel. The wind speed sensor monitors the airflow velocity entering the tunnel in real time and provides feedback to the controller, which controls the variable frequency fan to ensure stable airflow velocity entering the tunnel.

[0009] Preferably, the three-layer filtration system adopts a gradient density design, wherein the pre-filter, medium-efficiency filter, and high-efficiency filter all use a V-shaped filter plate structure layout, forming a staggered stepped arrangement. Changing the flat-panel filter to a V-shape provides a larger effective filtration area for air within the same frame size, and significantly reduces initial air resistance at the same airflow. The increased filtration area means that the same amount of dust is distributed across a larger filter media area, reducing the burden per unit area, increasing the airflow area, and lowering the air velocity per unit area. Simultaneously, the lower air velocity allows dust to be more gently adsorbed in the filter media, rather than being squeezed and penetrated by high-speed airflow. This extends the time it takes for the filter to reach its rated dust holding capacity, reducing replacement frequency, lowering consumable costs, and reducing maintenance workload. By reducing air velocity, the intensity of air friction and turbulence is directly reduced, also achieving noise reduction.

[0010] Preferably, the temperature control device is an electrically heated temperature control device. The temperature control device preferably uses a PTC ceramic heating element or a resistance wire heating module to provide minor temperature compensation for the air, compensating for slight deviations between the coarse adjustment of steam heating or cooling water cooling and the final requirement.

[0011] Furthermore, a flow equalization plate is provided at the junction of the buffer pipe and the spinning channel to ensure a uniform distribution of airflow velocity entering the spinning channel. The flow equalization plate has multiple circular or strip-shaped ventilation holes evenly distributed on it. By dispersing the airflow, the flow equalization plate ensures a uniform distribution of airflow velocity entering the spinning channel, avoiding fiber quality differences caused by localized overcooling or overheating.

[0012] Specifically, the heating device is a steam heating coil, which is connected to the factory's steam pipeline system via a first solenoid valve. The first solenoid valve is electrically connected to a controller. Preferably, the first solenoid valve is a proportional solenoid valve. Electric heating and other devices capable of heating air can also be used.

[0013] Specifically, the cooling device is a cooling water cooling coil, which is connected to the factory's circulating water cooling system via a second solenoid valve. The second solenoid valve is electrically connected to the controller. Preferably, the second solenoid valve is a proportional solenoid valve. Alternatively, a compression refrigeration system with a compressor and refrigerant can also be used.

[0014] Furthermore, the unit casing is equipped with maintenance windows at the locations of the primary filter layer, the medium-efficiency filter layer, and the high-efficiency filter layer. These maintenance windows are preferably openable, sealed windows, facilitating periodic replacement or cleaning of the filter layers.

[0015] Furthermore, the outer sides of the unit casing, heating pipes, cooling pipes, and buffer pipes are all wrapped with an insulation layer. The insulation layer is preferably polyurethane foam or rock wool to reduce heat loss of heated air during transport.

[0016] The advantages and beneficial effects of this utility model are as follows: 1. The external filter and the three-stage gradient density V-type filtration system intercept impurities of different particle sizes step by step, so that the air cleanliness entering the spinning tunnel reaches the "Class 100 / Class 1000 clean" standard. This effectively avoids problems such as spinneret blockage, fiber breakage, fuzz, surface defects, and uneven strength caused by impurities such as dust, oil mist, water vapor, and microorganisms in the air, thus improving fiber quality and production efficiency.

[0017] 2. By linking the initial temperature control unit, the constant temperature control unit, and sensors, the temperature fluctuation of the air at the spinning tunnel inlet is controlled within a suitable range, avoiding problems such as uneven fiber diameter, uneven strength, and abnormal shrinkage caused by temperature fluctuations, thus improving product quality.

[0018] 3. The controller collects temperature and wind speed data in real time and dynamically adjusts the operating status of each component to adapt to complex working conditions such as seasonal changes and fluctuations in the workshop environment. This ensures that the temperature, wind speed, and cleanliness of the air entering the spinning tunnel are constant, significantly improving fiber quality and fiber consistency.

[0019] 4. By using the factory's existing steam pipeline system and circulating water cooling system for initial temperature adjustment, and then maintaining the temperature through a constant temperature control unit, compared with the traditional method of first cooling and then heating for temperature regulation, not only is the temperature control more accurate, but it is also more energy-efficient and environmentally friendly. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the constant temperature and clean air handling system of this utility model; Figure 2 This is a flowchart of the constant temperature and clean air handling system of this utility model; Figure 3 This is a structural diagram of the flow equalization plate of this utility model.

[0021] In the diagram: 1. Unit casing; 101. Air inlet; 102. Filter screen; 201. Primary filter layer; 202. Medium-efficiency filter layer; 203. High-efficiency filter layer; 301. First temperature sensor; 311. Heating pipe; 312. Heating fan; 313. Steam heating coil; 314. First solenoid valve; 315. Steam piping system; 321. Cooling pipe; 322. Cooling fan; 323. Cooling water cooling coil; 324. Second solenoid valve; 325. Circulating water cooling system; 4. Buffer pipe; 5. Spinning tunnel; 601. Second temperature sensor; 602. Thermostatic device; 603. Variable frequency fan; 604. Wind speed sensor; 7. Maintenance window; 8. Insulation layer; 9. Flow equalization plate; 901. Ventilation hole. Detailed Implementation

[0022] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solution of this utility model and should not be construed as limiting the scope of protection of this utility model.

[0023] according to Figures 1-3 As shown, this utility model is a constant temperature and clean air treatment system for chemical fiber melt spinning process, including a unit housing 1. An air inlet 101 is provided on one side of the unit housing 1. An external filter 102 for preventing debris from entering the housing is provided at the air inlet 101. The unit housing 1 is provided with a three-layer filtration system, namely a primary filter layer 201, a medium-efficiency filter layer 202, and a high-efficiency filter layer 203. The primary filter layer 201 is preferably a polyester / polypropylene nonwoven fabric roll or a washable metal mesh, the medium-efficiency filter layer 202 is preferably a plate-type activated carbon filter or a bag-type activated carbon filter, and the high-efficiency filter layer 203 is preferably a HEPA filter. The system also includes a temperature pre-regulation unit, which comprises a first temperature sensor 301 disposed within the unit housing 1 for monitoring the internal air temperature, and a heating pipe 311 and a cooling pipe 321 disposed on one side of the unit housing 1. The heating pipe 311 is equipped with a heating fan 312 and a heating device, and the cooling pipe 321 is equipped with a cooling fan 322 and a cooling device. The ends of the heating pipe 311 and the cooling pipe 321 converge at a buffer pipe 4, which leads to the spinning tunnel 5. The system also includes a constant temperature regulation unit, which comprises a second temperature sensor 601 disposed at the end of the buffer pipe 4 near the spinning tunnel 5, a constant temperature device 602, and a variable frequency fan 603. A wind speed sensor 604 is disposed at the connection between the buffer pipe 4 and the spinning tunnel 5. The first temperature sensor 301, the second temperature sensor 601, the heating fan 312, the cooling fan 322, the variable frequency fan 603, and the wind speed sensor 604 are electrically connected to the controller.

[0024] The three-layer filtration system adopts a gradient density design, wherein the primary filter layer 201, the secondary filter layer 202, and the high-efficiency filter layer 203 all adopt a V-shaped filter plate structure layout, forming a staggered stepped arrangement. The structure of the primary filter layer 201, the secondary filter layer 202, and the high-efficiency filter layer 203 is preferably a non-parallel V-shaped filter plate structure, but it can also be a parallel V-shaped filter plate structure.

[0025] The constant temperature device 602 is an electrically heated constant temperature device.

[0026] The buffer pipe 4 leading to the spinning channel 5 is provided with a flow equalization plate 9 for uniformly distributing the airflow velocity entering the spinning channel 5. The flow equalization plate 9 has a plurality of circular or strip-shaped ventilation holes 901 evenly distributed on it. The shape of the ventilation holes 901 is preferably a hole structure with inconsistent front and rear flares.

[0027] The heating device is a steam heating coil 313, which is connected to the factory steam pipeline system 315 through a first solenoid valve 314. The first solenoid valve 314 is electrically connected to the controller.

[0028] The cooling device is a cooling water cooling coil 323, which is connected to the factory circulating water cooling system 325 through a second solenoid valve 324. The second solenoid valve 324 is electrically connected to the controller.

[0029] Maintenance windows 7 are provided in the housing 1 of the unit at the positions of the primary filter layer 201, the medium-efficiency filter layer 202, and the high-efficiency filter layer 203.

[0030] The outer sides of the unit casing 1, heating pipe 311, cooling pipe 321, and buffer pipe 4 are all wrapped with an insulation layer 8.

[0031] according to Figures 1-2 As shown, the working principle is as follows: When outside air enters the unit casing 1 through the air inlet 101, the external filter 102 intercepts large debris such as leaves and flying insects; then it passes sequentially through the pre-filter layer 201 (removing dust ≥5μm), the medium-efficiency filter layer 202 (removing pollen ≥1μm), and the high-efficiency filter layer 203 (removing particles ≥0.3μm), ultimately achieving an air cleanliness level of Class 100 / Class 1000. The pre-filter layer 201, medium-efficiency filter layer 202, and high-efficiency filter layer 203, arranged sequentially inside the casing, all adopt a V-shaped staggered stepped layout, effectively increasing the filtration area and reducing air resistance. Each filter layer is equipped with a maintenance window 7 with a sealing strip for easy and quick filter replacement.

[0032] After air enters the unit casing 1, the first temperature sensor 301 detects the temperature of the filtered air and sends it back to the controller. The controller compares this temperature with the temperature required for the process and determines one of the following three cases: When the air temperature inside the unit casing 1 is higher than the temperature required for process production, the controller opens the second solenoid valve 324, allowing the cooling water from the circulating water cooling system 325 to enter the cooling water cooling coil 323. The cooling fan 322 starts and draws outside air into the cooling pipe 321. After being processed by the cooling water cooling coil 323, the temperature is reduced to equal to or slightly lower than the temperature required for process production. Then the air enters the buffer pipe 4.

[0033] When the air temperature inside the unit casing 1 is lower than the temperature required for process production, the controller opens the first solenoid valve 314, allowing steam in the steam pipeline system 315 to enter the steam heating coil 313. The heating fan 312 starts and draws outside air into the heating pipeline 311. After being processed by the steam heating coil 313, the temperature is raised to be equal to or slightly lower than the temperature required for process production. Then the air enters the buffer pipeline 4.

[0034] When the air temperature inside the unit casing 1 is equal to or slightly lower than the temperature required for process production, the first solenoid valve 314, the second solenoid valve 324, the heating fan 312, and the cooling fan 322 are not started, and the air enters the buffer pipe 4 directly from the heating pipe 311 and the cooling pipe 321.

[0035] In actual operation, the above three scenarios will be dynamically adjusted based on the air temperature detected by the first temperature sensor 301. The first solenoid valve 314 and the second solenoid valve 324 are preferably electromagnetic proportional valves. By controlling the amount of coolant or steam entering or leaving the valve, the amount of temperature increase or decrease can be controlled. Since the accuracy of heating and cooling using steam or coolant is relatively low, this stage is the initial temperature regulation unit.

[0036] When air at a temperature equal to or slightly lower than the required temperature for the process enters the buffer pipe 4, its temperature will change slightly under the action of the insulation layer 8. As it passes the second temperature sensor 601 near the spinning tunnel 5, the sensor detects the air temperature about to enter the spinning tunnel 5 and transmits this information to the controller. The controller then activates the temperature control device 602 based on the temperature difference, thereby maintaining the temperature at the required level for the process. Simultaneously, the wind speed sensor 604 detects the wind speed within the channel and transmits this data to the controller. The controller determines the difference between the current wind speed and the required wind speed for the process, and thus controls the variable frequency fan 603 to maintain the air speed entering the spinning tunnel 5 after passing through the flow equalization plate 9 within a stable range. In the three scenarios of air processing by the initial temperature regulation unit, two scenarios use heating fan 312 and cooling fan 322, but their wind speeds are relatively low. In the other scenario, heating fan 312 and cooling fan 322 are not used. Therefore, the wind speed detected by wind speed sensor 604, which is not blown by frequency converter fan 603, is less than the wind speed required for process production.

[0037] After the above process, the temperature, wind speed and cleanliness of the air entering the spinning tunnel 5 are constant, thus ensuring the stability and consistency of the chemical fiber quality.

[0038] The bolts, nuts, screws, welding, and other related materials used in fixing and installing two or more parts described above are all known to those skilled in the art and will not be repeated here.

[0039] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A constant temperature and clean air treatment system for melt spinning of chemical fibers, characterized in that, The unit includes a housing (1), an air inlet (101) is provided on one side of the housing (1), an external filter (102) is provided at the air inlet (101) to prevent debris from entering the housing, and a three-layer filtration system is provided inside the housing (1), namely a primary filter layer (201), a medium-efficiency filter layer (202), and a high-efficiency filter layer (203). It also includes a temperature pre-conditioning unit, which includes a first temperature sensor (301) installed inside the unit housing (1) for monitoring the air temperature inside the housing, and a heating pipe (311) and a cooling pipe (321) installed on one side of the unit housing (1). The heating pipe (311) is equipped with a heating fan (312) and a heating device, and the cooling pipe (321) is equipped with a cooling fan (322) and a cooling device. The heating pipe (311) and the cooling pipe (321) converge at their ends to a buffer pipe (4), and the buffer pipe (4) leads to the spinning tunnel (5). It also includes a constant temperature control unit, which includes a second temperature sensor (601), a constant temperature device (602), and a variable frequency fan (603) located at the end of the buffer pipe (4) near the spinning channel (5). A wind speed sensor (604) is provided at the connection between the buffer pipe (4) and the spinning channel (5). The first temperature sensor (301), the second temperature sensor (601), the heating fan (312), the cooling fan (322), the variable frequency fan (603), and the wind speed sensor (604) are electrically connected to the controller.

2. The constant temperature and clean air treatment system for melt spinning of chemical fibers according to claim 1, characterized in that, The three-layer filtration system adopts a gradient density design, wherein the primary filter layer (201), the medium-efficiency filter layer (202), and the high-efficiency filter layer (203) all adopt a V-shaped filter plate structure layout, forming a staggered stepped arrangement.

3. The constant temperature and clean air treatment system for melt spinning of chemical fibers according to claim 1, characterized in that, The constant temperature device (602) is an electrically heated constant temperature device.

4. The constant temperature and clean air treatment system for melt spinning of chemical fibers according to claim 1, characterized in that, The buffer pipe (4) leading to the spinning channel (5) is provided with a flow equalization plate (9) for uniformly distributing the airflow velocity entering the spinning channel (5). The flow equalization plate (9) is provided with a plurality of circular or strip-shaped ventilation holes (901) evenly distributed on it.

5. A constant temperature and clean air treatment system for melt spinning of chemical fibers according to claim 1, characterized in that, The heating device is a steam heating coil (313), which is connected to the factory steam pipeline system (315) through a first solenoid valve (314). The first solenoid valve (314) is electrically connected to the controller.

6. A constant temperature and clean air treatment system for melt spinning of chemical fibers according to claim 1, characterized in that, The cooling device is a cooling water cooling coil (323), which is connected to the factory circulating water cooling system (325) through a second solenoid valve (324). The second solenoid valve (324) is electrically connected to the controller.

7. A constant temperature and clean air treatment system for melt spinning of chemical fibers according to claim 1, characterized in that, The unit casing (1) is provided with maintenance windows (7) at the positions of the primary filter layer (201), the medium filter layer (202), and the high efficiency filter layer (203).

8. A constant temperature and clean air treatment system for melt spinning of chemical fibers according to claim 1, characterized in that, The outer sides of the unit casing (1), heating pipe (311), cooling pipe (321), and buffer pipe (4) are all wrapped with a heat insulation layer (8).

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