Low Denier Polyester Cord Fabric High Modulus Spinning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current polyester cord fabrics for car tires lack improvements in reducing rolling resistance and fuel consumption, which are essential for meeting evolving tire performance standards, particularly in radial tires.
Innovation Solution
A method for producing polyester cord fabric with low denier and high modulus using a new weaving process and dipping method, involving high-speed spinning, twisting, and a two-bath dipping process with specific temperature and tension controls to enhance fiber orientation and modulus, reducing rolling resistance and improving tire performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional polyester cord fabric is used, then tire structure is maintained, but rolling resistance is high and fuel consumption increases
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional high-denier polyester yarn to low-denier polyester yarn (500-1000D) with specifically engineered high modulus properties. The spinning parameters are optimized with spinning speeds of 6000-6500m/min and heat roller temperatures of 100-150°C to achieve the desired parameter combination of low denier and high modulus, thereby reducing rolling resistance while maintaining strength
Solution Approach 2:
The patent implements local quality by applying different treatment conditions to different stages of the cord fabric production. The two-bath dipping process uses specific temperature ranges (first bath: 80-100°C, second bath: 120-140°C) and tension controls (0.5-2.0 daN) to selectively modify local properties of the fabric, enhancing modulus in critical areas while maintaining overall structural integrity
2Strength
If high modulus is achieved through conventional methods, then fiber strength is improved, but denier remains high increasing fabric weight
Solution Approach 1:
The patent fundamentally changes the parameter relationship between denier and modulus by using ultra-high speed spinning (6000-6500m/min) combined with specific heat roller temperatures (100-150°C). This parameter combination enables the production of low-denier yarns (500-1000D) that simultaneously achieve high modulus values, breaking the conventional trade-off where higher modulus required higher denier
Solution Approach 2:
The patent replaces conventional mechanical spinning methods with a modified system incorporating high-speed motors and precision heat rollers. This mechanical substitution enables the ultra-high speed spinning process that aligns polymer chains more effectively, achieving high modulus in low-denier yarns that would be impossible with traditional spinning equipment
3Quantity of substance
If spinning speed is increased to reduce denier, then fiber orientation is improved, but manufacturing precision becomes more difficult to control
Solution Approach 1:
The patent implements feedback control through the two-bath dipping process with precisely controlled temperatures and tensions. The first bath (80-100°C) and second bath (120-140°C) are sequentially applied with specific tension ranges (0.5-2.0 daN) to monitor and adjust the fiber properties, providing feedback control that maintains manufacturing precision even at ultra-high spinning speeds of 6000-6500m/min
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 method results in a polyester cord fabric with increased strength and modulus, reducing rolling resistance and fuel consumption, thereby enhancing tire performance and compliance with emerging tire standards.
Implementation Method 1
spinning, reducing melt discharge volume for extruding yarn with denier of 500 ̃1000 D; using high-speed motor and heat roller, and spinning speed of 6000 ̃6500 m/min to produce raw yarn
Implementation Method 2
using high-speed motor and heat roller, and spinning speed of 6000 ̃6500 m/min to produce raw yarn. Performing transformation of existing production line of high-modulus and low-shrinkage polyester
Implementation Method 3
performing dipping of the cord fabric using two-bath dipping method, adjusting the temperature of a key area to 250-260 degrees Celsius, the tension of the key area to 0.3 to 2.9 daN/each yarn
Implementation Method 4
tension and temperature design of the key area to achieve the purpose of high stretch and high retraction process of the cord fabric
Data Source
AI summary
The present invention discloses a preparation method of polyester cord fabric with low denier and high modulus, including steps of: spinning, reducing melt discharge volume for extruding yarn with denier of 500-1000 D; using high-speed motor and heat roller, spinning speed of 6000-6500 m/min to produce raw yarn; performing initial and repeat twisting of raw yarn by straight twisting machine; performing weaving of twisted yarn using Dornier air-jet loom to produce cord fabric, when weaving and reeding-in, using two into a reed way, adding creel roller bearing and creel single spindle tension control belt to improve uniformity; performing dipping of cord fabric using two-bath dipping, adjusting temperature to 250-260 degrees Celsius, tension to 0.3-2.9 daN/each yarn of key area, running speed of yarn to 55-70 m/min. The polyester cord fabric with low denier and high modulus can reduce rolling resistance and fuel consumption, and improve performance.