Whirling Air Spinning Lubricant Composition for Scum Suppression
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Solution Overview
Problem
High-speed spinning processes, particularly with whirling air spinning machines, face significant scum accumulation issues that shorten cleaning cycles and reduce operational performance, leading to yarn strength deterioration and increased breakage due to rapid fiber damage and white powder formation, which conventional fiber-processing agents using alkyl phosphoric ester potassium salts fail to adequately address.
Innovation Solution
A spinning method utilizing a fiber-processing agent with a kinematic viscosity of 1 x 10^-6 to 100 x 10^-6 m^2/s, comprising aliphatic ester compounds, linear polyorganosiloxanes, and mineral oils, mixed with compressed air and sprayed onto fibers in a whirling air spinning machine to suppress scum accumulation and ensure high-speed spinning performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fiber-processing agents using alkyl phosphoric ester potassium salt are used, then spinning performance is improved, but scum accumulation increases on spindle tips and holders
Solution Approach 1:
The invention changes the chemical composition parameters of the fiber-processing agent by replacing alkyl phosphoric ester potassium salt with specific lubricants (aliphatic ester compounds with carbon numbers 5-70, linear polyorganosiloxanes, and mineral oils) that have different molecular structures and surface properties, thereby eliminating scum accumulation while maintaining spinning performance
Solution Approach 2:
The invention uses a composite fiber-processing agent comprising multiple types of lubricants (aliphatic ester compounds, linear polyorganosiloxanes, and mineral oils) in specific ratios to achieve synergistic effects that prevent scum accumulation on spindle surfaces during high-speed spinning
2Productivity
If spinning speed is increased to improve productivity, then production efficiency increases, but scum accumulation increases and cleaning cycle shortens
Solution Approach 1:
The invention changes the lubricant composition parameters to materials with appropriate viscosity and surface activity that remain effective at high spinning speeds, preventing scum accumulation even under increased production conditions
Solution Approach 2:
The fiber-processing agent acts as a consumable material that is continuously applied to prevent scum accumulation during high-speed operation, effectively replacing the need for frequent cleaning cycles
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively suppresses scum accumulation on spindle tips and holders, maintaining high-speed spinning performance and yarn quality by evenly distributing the fiber-processing agent, thereby reducing the need for frequent cleaning and minimizing fiber damage.
Implementation Method 1
mixing a fiber-processing agent with compressed air in the whirling air spinning machine and spraying the fiber-processing agent on fibers
Data Source
AI summary
A spinning method using a whirling air spinning machine enables successful operation under high-speed spinning conditions with scum accumulation suppressed to a good extent. Spun yarns obtained with the spinning method are also provided. A fiber-processing agent having a kinetic viscosity at 30°C of 1 x 10-6 to 100 x 10-6 m2/s is mixed with compressed air in a whirling air spinning machine and is sprayed on fibers in said spinning method using the whirling air spinning machine, wherein the said fiber-processing agent comprises one, two or more of the following lubricant (A), the following lubricant (B) and the following lubricant (C). Lubricant (A) is an aliphatic ester compound of carbon number 5-70; Lubricant (B) is a linear polyorganosiloxane having a kinetic viscosity at 30°C of 5 x 10-6 to 100 x 10-6 m2/s; and Lubricant (C) is a mineral oil having a kinetic viscosity at 30°C of 5 x 10-6 to 100 x 10-6 m2/s.