Compact Wet Spinning Module for Chemical Fibres
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Solution Overview
Problem
Existing wet spinning modules for chemical fibers are inefficient in producing small-sized tows due to high localized stresses on fibers, complex tow drawing-in operations, and increased module height, which limits productivity and increases economic losses.
Innovation Solution
A compact wet spinning module design featuring a zig-zag path for fibers with horizontal rectilinear lengths between drive rollers, spillway-type treatment trays for washing and finishing without tow deviation, and drive rollers and diverter rollers pivoted on a single vertical support plate for reduced module width and height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional horizontal in-line spinning processes are used, then large fibre tows can be produced with high production capacity, but the module width is limited to about 1.8 metres and processing speed is limited to up to 500 m/min
Solution Approach 1:
The patent transitions from horizontal in-line processing to vertical module spinning, changing the spatial dimension from horizontal development to vertical development. This allows multiple tows to be processed in parallel within a compact horizontal footprint while achieving high processing speeds up to 6,000 m/min, resolving the contradiction between production capacity and processing speed.
2Quantity of substance
If conventional horizontal in-line spinning processes are used, then many parallel tows can be processed, but the break of a single tow causes disturbance on all adjacent tows and requires halting the entire line
Solution Approach 1:
The patent divides the spinning system into independent vertical modules, each processing a small number of tows (2-8 tows per module). This segmentation isolates failures so that a break in one module does not affect other modules, maintaining line stability while processing many tows overall through parallel operation of multiple modules.
Solution Approach 2:
By transitioning from horizontal arrangement where tows are closely packed and interdependent, to vertical modular arrangement where tows are spatially separated into independent modules, the patent eliminates the propagation of disturbances between adjacent tows while maintaining high throughput through parallel processing.
3Device complexity
If conventional horizontal in-line spinning processes are used, then processing can be performed with simple equipment arrangement, but the risk of tow instability and breaks increases at higher speeds
Solution Approach 1:
The patent employs vertical module spinning with a compact equipment arrangement where drive rollers and treatment devices are vertically stacked. This configuration maintains simple equipment layout while achieving high speeds up to 6,000 m/min with improved tow stability through vertical processing architecture and reduced horizontal tow interactions.
4Quantity of substance
If conventional horizontal in-line spinning processes are used, then large fibre tows can be produced, but the production of small-sized tows is anti-economical with capacity reduced up to 60 times
Solution Approach 1:
The patent segments the production system into multiple independent vertical modules, each optimized for producing small-sized tows (1K tow with 900/1550 dtex count). By paralleling many such modules, the system achieves high overall productivity for small tows that would be anti-economical in conventional horizontal lines, as each module operates independently at optimal parameters for small tow production.
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 compact module design enhances fiber quality by reducing anisotropies and stress on fibers, simplifies tow drawing-in operations, and significantly reduces the module's width and height, thereby increasing productivity and reducing economic losses associated with tow breaks.
Implementation Method 1
subsequent extrusion of the spinning solution within a suitable aqueous solution which causes the coagulation thereof by solvent removal
Data Source
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AI summary
Compact module for wet spinning of chemical fibres of the type comprising a spinning head (F) of 2-8 tows (S), each one consisting of a plurality of continuous filaments, relative supply pumps (P) of the spinning solution, a coagulation tank (V) containing a coagulation solution, and a plurality of drive rollers (2) and respective idle diverter rollers (3) which determine a zigzag path of the tows (S) downstream of the spinning area, in the rectilinear lengths of which liquid-based treatments are carried out on said tows (S). The rectilinear lengths of said zigzag path are horizontal and said liquid-based treatments on the tows (S) are carried out in horizontal treatment trays (4) of the spillway type.