Melt Spinning Device for Multicolored Composite Yarn
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Solution Overview
Problem
Existing methods for producing multicolored carpet yarns in melt-spinning processes lack flexibility and uniformity, limiting the range of color effects and filament mixing due to turbulence and rigid filament behavior after texturing.
Innovation Solution
A method and device that allow for individual treatment of partial threads at each stage, including pre-interlacing, post-interlacing, and crimping, with adjustable process parameters for air pressure and fluid temperature and pressure control, enabling separate or combined treatment of threads to create diverse color patterns and properties, and mechanical mixing before stretching for enhanced color separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If partial threads are swirled several times before crimping with pre-interlacing and post-interlacing, then different color effects can be realized in the composite thread, but the process complexity increases and flexibility is reduced
Solution Approach 1:
The patent applies preliminary action by performing pre-interlacing before stretching to create an initial filament bond, then partially eliminating this bond during stretching, and finally creating new color patterns through subsequent separate twirling and crimping. This staged approach allows different color effects to be achieved while managing process complexity through systematic preparation and treatment at each stage.
2Stability of the object's composition
If partial threads are cooled with cooling medium after texturing, then the filaments become rigid and easier to handle, but filament mixing is limited due to increased rigidity
Solution Approach 1:
The patent applies dynamics by making the cooling process conditional rather than continuous. Cooling is applied selectively at specific stages (after extrusion and after texturing) while maintaining warmer temperatures during intermediate handling and mixing stages. This dynamic temperature control allows filaments to be rigid when needed for handling but flexible when mixing is required, resolving the contradiction between stability and adaptability.
3Productivity
If multiple partial threads are merged into a partial composite thread early in the process, then production efficiency increases, but the ability to treat individual threads separately is reduced
Solution Approach 1:
The patent applies segmentation by dividing the treatment process into distinct stages where partial threads can be treated individually (pre-interlacing, stretching, separate twirling, crimping) before being merged into the final composite thread. This segmented approach maintains individual thread treatment capability while achieving high productivity through systematic parallel processing of multiple partial threads through the same treatment stages.
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
Enables the production of a wide range of multicolored composite threads with high color separation in a single-stage process, eliminating the need for downstream secondary processes and achieving high production speeds with improved physical properties.
Implementation Method 1
several colored polymer melts are fed into extrusion nozzles and extruded as colored filament bundles
Implementation Method 2
The freshly extruded filaments are cooled in a cooling device
Implementation Method 3
the partial threads are swirled several times before they are crimped. A so-called pre-interlacing takes place
Implementation Method 4
the filament bond created by the pre-interlacing is partially eliminated
Implementation Method 5
After the stretching and before the crimping, post-interlacing takes place, with the post-interlacing nozzles being controllable separately from one another for the separate interlacing of the filaments
Implementation Method 6
which are then crimped when the individual threads and the partial thread are textured separately
Data Source
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AI summary
The invention relates to a method for producing a crimped, multicolored composite thread in a melt spinning method and to a melt spinning apparatus for carrying out the method. According to the invention, a plurality of colored filament bundles are initially extruded separately, cooled and each combined into a partial thread. The partial threads are then separately pre-swirled and stretched individually or as a partial composite thread formed from a plurality of partial threads. A separate post-swirling of individual partial threads or of the partial composite thread and a separate crimping of the partial threads or of the partial composite thread then occurs. After the crimping, the partial threads and the partial composite thread are combined into a composite thread and wound into a coil. The melt spinning apparatus according to the invention has a pre-swirling apparatus having a plurality of swirling nozzles, a post-swirling device having a plurality of post-swirling nozzles and a crimping device having a plurality of texturing nozzles, wherein the nozzles are designed such that an individual partial thread or a partial composite thread formed from a plurality of partial threads can optionally be processed.