False Twist Nanofiber Yarn Spinner Speed

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Solution Overview

Problem

The existing true twist method for spinning nanofiber yarns is inefficient, requiring extremely high rotational speeds and resulting in slow production rates, which is not economically viable and leads to an imbalance between nanofiber forest production and yarn production, making it challenging to design a continuous processing system.

Innovation Solution

The implementation of a false twist method, where a twist is introduced to an untwisted nanofiber strand by applying a force perpendicular to the longitudinal axis, using a silicone rubber surface with a specific coefficient of friction and surface energy, allowing for lower rotational speeds and increased production rates, aligning with nanofiber forest production rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If true twist method is used to spin nanofiber yarn, then yarn strength and fiber binding are improved, but rotational speed must be extremely high and production rate is slow

Engineering Contradiction:

Improveyarn strengthVSAvoidproduction rate

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent inverts the conventional true twist approach by using false twist method. Instead of twisting fibers continuously at extremely high rotational speeds through the entire yarn length, the false twist method applies twist locally and then sets it, allowing the yarn to be produced at much lower rotational speeds (30-100 RPM vs. thousands of RPM) while maintaining adequate fiber binding and yarn strength.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The false twist spinning process segments the twisting action into distinct phases: twist introduction, twist setting, and twist relaxation. This segmentation allows the twisting operation to be performed at lower speeds with brief contact times (less than 5 milliseconds), dramatically improving production rate while still achieving the necessary fiber binding through the twist-set-relax cycle.

Inventive Principle:

Principle #1Segmentation

2Strength

If true twist method is used, then fiber binding is achieved, but equipment cost and complexity increase due to extremely high rotational speed requirements

Engineering Contradiction:

Improvefiber bindingVSAvoidequipment complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the complex high-speed true twist mechanism with a simpler false twist system. The false twist spinner uses a twisting element that contacts the yarn briefly at low speed, eliminating the need for extremely high rotational speed equipment while still achieving adequate fiber binding through the false twist mechanism.

Inventive Principle:

Principle #13The other way round (Inversion)

3Stability of the object's composition

If true twist method is used, then continuous yarn is produced, but production rate is slow and cannot match nanofiber forest production rates

Engineering Contradiction:

Improvecontinuous yarn productionVSAvoidyarn production rate

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The false twist spinning system dynamically adjusts the twist application and release throughout the yarn production process. The twisting element is brought into contact with the yarn for brief periods (less than 5 milliseconds) and then removed, allowing continuous yarn production at high speeds that can match nanofiber forest production rates, unlike the static high-speed continuous twisting of true twist methods.

Inventive Principle:

Principle #15Dynamics

4Productivity

If high rotational speed is used in true twist, then yarn is formed, but equipment costs and potential damage increase

Engineering Contradiction:

Improveyarn formation rateVSAvoidequipment damage and cost

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the speed approach by using low rotational speeds (30-100 RPM) with false twist instead of extremely high speeds. This inversion dramatically reduces equipment wear, maintenance costs, and potential damage while still achieving adequate yarn formation through the false twist mechanism that sets twist during brief contact periods.

Inventive Principle:

Principle #13The other way round (Inversion)

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

This approach enables nanofiber yarn production at rates of at least 30 m/min with lower rotational speeds, reducing equipment costs and potential damage, while ensuring uniform consistency and improved mechanical, electrical, and physical properties of the yarn.

Implementation Method 1

In one embodiment, wherein applying the force comprises contact between the untwisted nanofiber strand and the twisting surface. In one embodiment, wherein the contact between the untwisted nanofiber strand and the twisting surface occurs during less than 5 milliseconds.

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11913142B2Nanofiber yarn spinning system

Publication Date: 2024.02.27 LINTEC OF AMERICA INC

AI summary

Systems for fabricating nanofiber yarn at rates of at least 30 m/min (1.8 kilometers (km)/hour (hr)) using a “false twist” nanofiber yarn spinner and a false twist spinning technique are disclosed. In a false twist spinning technique, a twist is introduced to nanofibers in a strand by twisting the nanofibers at points between ends of the strand. This is in contrast to the “true twist” technique where one end of a strand is fixed and the opposing end of the strand is rotated to introduce the twist to intervening portions of yarn.