Composite Spinneret Layout to Prevent Fiber Discharge Bending
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Solution Overview
Problem
Existing composite spinnerets for manufacturing latent crimp-expressing fibers face issues with discharge bending phenomena, asymmetrical velocity distributions, and reduced productivity, leading to unstable yarn manufacturing and limited crimp-expressing properties.
Innovation Solution
A composite spinneret design with a measurement plate, distribution plates, and a discharge plate that form an eccentric core-sheath cross-section, controlling polymer flow to inhibit discharge bending and maintain crimp-expressing properties, ensuring stable discharge across various conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional composite spinneret is used to manufacture latent crimp-expressing fibers, then the discharge bending phenomenon occurs and asymmetrical velocity distribution arises, but the manufacturing precision and reliability of yarn production deteriorate
Solution Approach 1:
The patent applies asymmetry by designing the spinneret with an eccentric core-sheath cross-section where the core component is positioned off-center relative to the sheath component. This asymmetric configuration creates a specific velocity distribution pattern that prevents discharge bending, allowing the polymer streams to merge smoothly without the asymmetrical velocity distribution that plagues conventional symmetric spinneret designs.
Solution Approach 2:
The patent implements local quality by creating distinct regions within the spinneret cross-section with different flow characteristics. The core component has different flow properties than the sheath component, and the eccentric positioning creates localized flow patterns that optimize the merging process. This local differentiation of flow qualities prevents the discharge bending phenomenon while maintaining manufacturing simplicity.
2Device complexity
If the spinneret design is simplified to improve ease of manufacture, then device complexity is reduced, but the ability to control discharge bending and maintain crimp-expressing properties deteriorates
Solution Approach 1:
The eccentric core-sheath spinneret design achieves reliability without increased complexity by using a straightforward asymmetric geometry. The core component is simply positioned off-center in the sheath, creating a natural flow guidance system that prevents discharge bending. This asymmetric design is more reliable than complex symmetric designs with multiple adjustment mechanisms, as it provides inherent flow control through its geometric configuration alone.
3Productivity
If conventional spinneret designs are used, then discharge bending occurs and asymmetrical velocity distribution arises, but productivity is reduced due to unstable yarn manufacturing
Solution Approach 1:
The eccentric core-sheath configuration improves productivity by eliminating discharge bending through its asymmetric geometry. This prevents the formation of asymmetrical velocity distributions that cause yarn instability, allowing for continuous stable production. The design achieves both high productivity and reliability simultaneously by using the asymmetric arrangement to create inherently stable flow patterns throughout the spinning process.
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 solution enables the production of stretch yarns with controlled crimp forms, providing excellent stretchability, motion followability, and a flexible surface feel, while maintaining dimensional stability and crimp-expressing properties, suitable for a wide range of applications including sports and apparel clothing.
Implementation Method 1
When two kinds of polymers having different melt viscosities are spun using the composite spinneret, a polymer on a high viscosity side is pressed by a polymer on a low viscosity side, a discharge bending phenomenon in which the composite polymer is discharged in a bent state occurs
Data Source
AI summary
A composite spinneret for discharging a composite polymer flow comprising a first component polymer and a second component polymer includes a measurement plate having a plurality of measurement holes for measuring each polymer component, one or more distribution plates having distribution holes for distributing each polymer component, and a discharge plate. In a lowermost layer downstream in a polymer spinning path, a polymer distribution hole group is formed in which a plurality of semicircularly arranged first component polymer distribution holes are surrounded by second component polymer distribution holes. At least some of the second component polymer distribution holes are arranged in a semicircular arc on an outer side of the circumferential portion of the first component holes. The number Ho of the arc-arranged second component holes relative to the total number Ht of second component holes in the group satisfies 1/16<Ho/Ht<¼.