Molding Solution Dilution for Viscosity Control
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Solution Overview
Problem
Existing methods for producing spinning solutions, such as those for viscose and lyocell fibers, are limited by the need for low viscosity and low cellulose content, which reduces process effectiveness and requires separate reactors for solution production and molding, leading to inefficiencies.
Innovation Solution
The diluent is introduced upstream or within the discharge device, allowing the molding solution to be diluted to the desired viscosity just before processing, enabling storage and direct feeding to a molding device, and using a tertiary amine oxide as solvent with monitoring via optical index for better mixing and concentration control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the molding solution is produced with low viscosity and low cellulose content, then the spinning process can be performed, but the process effectiveness is reduced and separate reactors are required
Solution Approach 1:
The patent combines the solution production reactor and the molding reactor into a single integrated device. The kneading reactor produces high-viscosity molding solution directly at the desired cellulose concentration, eliminating the need for separate solution preparation and molding reactors. This merging of functions resolves the contradiction by maintaining high productivity through integrated processing while reducing device complexity by removing redundant reactor components.
2Manufacturing precision
If the molding solution is stored temporarily, then it can be processed at optimal viscosity, but additional storage equipment is required
Solution Approach 1:
The patent performs preliminary action by producing the molding solution directly at the optimal viscosity and cellulose concentration within the kneading reactor before discharge. The diluent is added upstream or within the discharge device, ensuring the solution is ready for immediate processing without requiring temporary storage in buffer vessels. This preliminary preparation resolves the contradiction by achieving precise viscosity control through controlled dilution while eliminating the need for additional storage equipment.
3Stability of the object's composition
If the diluent is added early in the process, then mixing is improved, but the viscosity control during discharge is compromised
Solution Approach 1:
The patent segments the dilution process into distinct stages: the base molding solution is first produced with optimal mixing quality in the kneading reactor, then diluent is added separately upstream or within the discharge device. This segmented approach allows independent optimization of mixing quality during solution production and viscosity control during discharge, resolving the contradiction by preventing interference between these two critical functions.
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
This approach simplifies the process by maintaining high viscosity in kneading reactors, allowing for efficient production of molded articles with desired properties, such as fibers or nonwovens, and improves mixing and retention of the molding solution for better processing outcomes.
Implementation Method 1
monitoring via optical index for better mixing and concentration control
Data Source
AI summary
A method for production of a molded article from a base substance in a device for mixing of the base substance with a solvent is provided. The method includes mixing a base substance to produce a molding solution with the solvent and at least partially removing the solvent from the mixture; and feeding the molding solution to a device for further processing of a product and diluting the molding solution before further processing. In embodiments, the diluent is introduced to the device before a discharge device and/or in the discharge device.