Polyester FDY Profiled Fiber Alignment to Reduce Lousiness
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Solution Overview
Problem
The production of profiled cross-section fibers in the polyester FDY process is prone to high lousiness due to the fixed positions of wire guide ceramic pieces, leading to filament bundle misalignment, collisions, and uneven oiling, which affects product quality.
Innovation Solution
Adjustable horizontal and longitudinal positions of wire guide ceramic pieces are implemented to maintain vertical alignment of the filament bundle, using fiber optic sensors to detect jitter conditions and adjust the pre-entangling device parameters for optimal jitter effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed equidistant wire guide ceramic pieces are used in the pre-entangling device, then the device structure is simple, but the filament bundle cannot remain vertical and collides with ceramic pieces causing lousiness
Solution Approach 1:
The patent applies the dynamics principle by making the wire guide ceramic pieces adjustable rather than fixed. The ceramic pieces can be positioned at different horizontal and longitudinal distances to adapt to different filament bundle characteristics, allowing the system to dynamically optimize alignment and prevent collisions that cause lousiness.
Solution Approach 2:
The patent implements parameter changes by varying the horizontal and longitudinal positions of the wire guide ceramic pieces. By adjusting these spatial parameters, the system optimizes the filament bundle's vertical alignment and jitter effect, resolving the contradiction between structural simplicity and manufacturing precision.
2Device complexity
If fixed distance between upper and lower rows of wire guide ceramic pieces is used, then the device structure is simple, but the jitter distance cannot be changed and optimal jitter effect cannot be achieved
Solution Approach 1:
The patent applies dynamics by enabling adjustable distances between the upper and lower rows of wire guide ceramic pieces. This allows the jitter distance to be optimized for different filament bundle characteristics, ensuring uniform oiling and sufficient bonding force while maintaining structural adaptability.
Solution Approach 2:
The patent implements parameter changes by allowing the longitudinal distance between wire guide rows to be adjusted. This parameter optimization ensures the filament bundle achieves the best jitter effect, preventing both insufficient oiling and excessive entanglement that would compromise reliability.
3Manufacturing precision
If entangling pressure is increased to disperse oil agent evenly, then oiling uniformity improves, but monofilaments entangle and collide causing lousiness and loose loop yarn
Solution Approach 1:
The patent applies parameter changes by optimizing the entangling pressure within a specific range (0.02-0.06 MPa) and combining it with adjusted wire guide ceramic piece positions. This coordinated parameter optimization achieves uniform oiling while preventing monofilament entanglement and the resulting lousiness.
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
Significantly reduces lousiness in profiled cross-section fibers by ensuring vertical alignment and optimal jitter, improving product quality and reducing loose loop yarns and entanglement.
Implementation Method 1
the entangling compressed-air sprays air flow through nozzles of the pre-entangling device in the pre-entangling yarn path to scatter and jitter the filament bundle
Implementation Method 2
using fiber optic sensors to detect jitter conditions
Data Source
AI summary
A method for preparing profiled fibers with low lousiness rate by a polyester FDY process is provided, when preparing profiled fibers by the FDY process, during the operation of a yarn path, the horizontal and longitudinal positions of wire guide ceramic pieces on the pre-entangling wire guide frame are adjusted to maintain vertical alignment of the filament bundle in the pre-entangling device and achieve optimal jitter effect, to prepare profiled fibers with a low lousiness rate; when the profiled fibers are triangular profiled fibers, the lousiness rate is 0.35-0.65%; when the profiled fibers are trilobal profiled fibers, the lousiness rate is 0.85-1.25%; when the profiled fibers are flat profiled fibers, the lousiness rate is 0.5-0.85%.