Fiber Sizing Applicator Filtration for Cleaner Coating Control
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Solution Overview
Problem
Prior sizing applicators for rapidly moving fibers suffer from degradation of sizing due to radiant heat, contamination by dust and fiber particles, leading to fiber breaks, incomplete sizing, and undesirable product variation, which increases manufacturing costs and reduces productivity.
Innovation Solution
A sizing applicator with a filtered sizing liquid distribution system and continuous cleaning mechanism to remove foreign objects and unused sizing from the fiber coating element, preventing re-contamination and degradation by relocating the materials to a cooler area for filtering and re-use or disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the applicator is made larger and wider to accommodate more fibers from a bushing, then the fiber production capacity is improved, but the likelihood of foreign matter collection and sizing degradation increases
Solution Approach 1:
The harmful element (foreign matter and degraded sizing) is extracted from the system by implementing a continuous cleaning mechanism that removes contaminants from the applicator roll surface. This allows the applicator to maintain large size for high productivity while preventing the accumulation of harmful substances that would otherwise degrade sizing quality.
Solution Approach 2:
The cleaning mechanism operates continuously to maintain the applicator roll surface, ensuring that sizing application remains effective throughout the entire production process. This continuous action prevents intermittent sizing failures that would occur with periodic cleaning, thereby maintaining both high productivity and sizing quality throughout operation.
2Productivity
If the applicator is exposed to radiant heat from bushings to maintain processing temperature, then the fiber processing efficiency is improved, but the sizing degrades and forms globules
Solution Approach 1:
The degraded sizing and globules are continuously removed from the applicator roll surface by the cleaning mechanism, extracting the harmful effects of heat exposure before they can significantly impact sizing quality. This allows the system to operate in the hot environment necessary for efficient fiber processing while maintaining sizing integrity.
Solution Approach 2:
The cleaning mechanism provides continuous feedback control of the sizing application quality by removing degraded material and ensuring uniform sizing distribution. This feedback loop maintains sizing stability despite the thermal stress from radiant heat exposure, preventing the accumulation of viscosity variations and globule formation.
3Object-affected harmful factors
If dust and fiber particles contact the sizing reservoir, then contamination occurs, but the particles are washed off into the sizing and reapplied to the fiber
Solution Approach 1:
The cleaning mechanism continuously extracts and removes particles and contaminated sizing from the applicator roll surface, preventing re-contamination of the fiber. This extraction process eliminates the cycle where particles are washed off into the sizing and reapplied, thereby resolving the harmful effect of re-contamination.
Solution Approach 2:
The cleaning mechanism acts as an intermediary between the contaminated sizing reservoir and the fiber, intercepting and removing particles before they can be reapplied to the fiber. This intermediary function breaks the contamination cycle and protects the fiber quality despite the presence of dust and particles in the sizing reservoir.
4Reliability
If high viscosity sizing and globules are present on the applicator element, then fiber breaks and incomplete sizing occur, but the presence of these contaminants is difficult to eliminate
Solution Approach 1:
The continuous cleaning mechanism operates without interruption to continuously remove high viscosity sizing and globules from the applicator roll surface. This continuous action ensures that contaminants are eliminated as they form, maintaining fiber integrity and sizing completeness without requiring complex intermittent cleaning systems or manual intervention.
Solution Approach 2:
The cleaning mechanism is designed to automatically remove contaminants from the applicator roll surface without external intervention. The system serves itself by continuously cleaning the application surface, eliminating the need for complex manual cleaning procedures or sophisticated contaminant detection and response systems.
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 significantly reduces fiber breakage, improves product uniformity, and decreases manufacturing costs by maintaining a consistent sizing application, reducing waste, and extending the life of the fiber coating elements.
Implementation Method 1
a device for cleaning the fiber coating element at a location downstream of the fiber coating location
Implementation Method 2
filtered sizing liquid distribution system
Implementation Method 3
relocating the materials to a cooler area for filtering and re-use or disposal
Data Source
AI summary
Disclosed are fiber coating sizing applicator apparatus having a member to remove unused sizing and foreign objects from the fiber coating element of the applicator on a continuous or intermittent basis. Also disclosed are sizing applicators having as part of the drive, a servo motor for reduced variation in sizing application. Unused sizing is filtered to remove foreign objects and returned the applicator right away, or stored in a temperature controlled area until ready to feed back to a sizing applicator. Also disclosed are methods of using the sizing applicator apparatus to produce sized fibers. The apparatus and methods of the invention produce a substantial reduction in the fiber break rate, sizing usage and applicator maintenance.