Melt-Spun Filament Color Variation via Polymer Flow Control
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Solution Overview
Problem
Existing methods for creating color variation in bundles of filaments are time-consuming and wasteful, and they struggle to achieve consistent and efficient color changes along the length of the filament.
Innovation Solution
A system comprising N extruders, at least one spin station, and a processor that adjusts the volumetric flow rate of polymers pumped by spin pumps to achieve specific ratios of polymers in the filaments, thereby creating a color variation along the length of the filament.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dye sourcing is changed to create color variation in filaments, then color variation is achieved, but the process becomes time-consuming and wasteful
Solution Approach 1:
The patent applies preliminary action by incorporating color variation directly into the polymer material before filament formation. Different colored polymers are pre-mixed in specific ratios using computer-controlled extruders, so the color variation is already established before spinning begins. This eliminates the need to stop and change dye sources during production, resolving the time-consuming issue while maintaining color variation.
Solution Approach 2:
The patent replaces the mechanical/dmanual process of changing dye sources with an automated computer-controlled system. The processor monitors and adjusts the flow rates of different colored polymers in real-time, substituting manual intervention with automated control. This reduces both time loss and material waste from frequent setup changes.
2Ease of manufacture
If dye sourcing is changed to create color variation in filaments, then color variation is achieved, but material waste increases
Solution Approach 1:
The patent applies preliminary action by incorporating color variation directly into the polymer material before filament formation. Different colored polymers are pre-mixed in specific ratios using computer-controlled extruders, so the color variation is already established before spinning begins. This eliminates the need to stop and change dye sources during production, resolving the time-consuming issue while maintaining color variation.
Solution Approach 2:
The patent replaces the mechanical/dmanual process of changing dye sources with an automated computer-controlled system. The processor monitors and adjusts the flow rates of different colored polymers in real-time, substituting manual intervention with automated control. This reduces both time loss and material waste from frequent setup changes.
3Manufacturing precision
If spin pump speeds are adjusted to achieve color variation, then color ratio control is improved, but system complexity increases
Solution Approach 1:
The patent applies universality by using a single computer-controlled system to manage multiple spin pumps simultaneously. The processor executes computer-readable instructions that coordinate all extruders and spin pumps, allowing one control system to perform the function of multiple individual controllers. This maintains manufacturing precision while managing system complexity through integrated control.
Solution Approach 2:
The patent implements feedback through the computer-controlled system that monitors and adjusts spin pump speeds in real-time. The processor receives data on polymer flow rates and makes automatic adjustments to maintain precise color ratios. This closed-loop control ensures manufacturing precision while the automation handles the complexity of coordinating multiple pumps.
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 system enables efficient and consistent color variation in filaments, reducing waste and improving production speed by allowing for continuous filament formation without the need to stop and change dye sources.
Implementation Method 1
The processor is in electrical communication with the N spin pumps and is configured to execute computer readable instructions that cause the processor to adjust the volumetric flow rate of the polymers pumped by each spin pump to achieve a ratio of the polymers to be included in a yarn comprising the filaments spun from the spinneret
Implementation Method 2
Each spin station includes at least one spinneret through which a plurality of melt-spun filaments are spun from at least two of the molten polymer streams received by the spin station
Data Source
AI summary
Systems for producing M yarns, wherein M≥1, include N extruders, M spin stations, and a processor, wherein N>1. Each extruder includes a polymer having a color, hue, luster, and/or dyeability characteristic, which are different from each other. Each spin station produces one yarn comprising at least one bundle of filaments. Each spin station comprises at least one spinneret through which filaments are spun from at least two molten polymer streams received by the respective spin station and N spin pumps upstream of the spinneret for the respective spin station. Each spin pump is paired with one of the N extruders. The processor is in electrical communication with the N*M spin pumps and is configured to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in each M yarn.