Multiple Fiber Spinning Apparatus for Conjugate Polymer Processing
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Solution Overview
Problem
Conventional melting conjugate spinning apparatuses are limited in producing fibers with multiple kinds of polymer raw materials, leading to reduced productivity and increased production costs, as they cannot efficiently spin three or more kinds of polymers into fibers with varied patterns and cross-sectional structures.
Innovation Solution
A multiple fiber spinning apparatus is designed with a plurality of extruders, gear pumps, and spinning nozzles, along with a flow passage unit and electric heater, allowing for the simultaneous melting and spinning of multiple polymers into fibers, enabling the production of conjugate or intermingled fibers with varied thicknesses and cross-sectional shapes without the need for a separate intermingling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional melting conjugate spinning apparatus is used, then fiber spinning process is simple, but it cannot produce multiple conjugate fiber containing three or more kinds of polymer raw materials
Solution Approach 1:
The apparatus is divided into multiple independent extruder units (first, second, third extruders) each capable of processing different polymer materials. Each extruder has its own gear pump and flow passage system, allowing three or more different polymers to be independently fed, melted, and controlled into the spinning nozzle simultaneously.
Solution Approach 2:
The spinning nozzle is designed with a universal structure that receives molten polymer from multiple gear pumps through different flow passages. The nozzle can simultaneously process and combine multiple different polymer materials into a single conjugate fiber, making it multi-functional rather than dedicated to a single polymer type.
2Productivity
If separate intermingling process is used for intermingled fiber production, then fiber properties can be varied, but work complexity increases and productivity decreases
Solution Approach 1:
The apparatus merges the conjugate spinning process and the intermingling process into a single integrated operation. Multiple extruders feed different polymers that are combined in the spinning nozzle to directly produce intermingled fibers, eliminating the need for a separate post-spinning intermingling process and thereby increasing productivity.
Solution Approach 2:
The different polymer materials are fed and pre-melted in separate extruders before entering the spinning nozzle, where they are combined in the desired intermingled pattern. This preliminary separation and preparation of materials allows for controlled intermingling during the spinning process itself rather than requiring a separate subsequent process.
3Adaptability or versatility
If flow passages are designed for multiple polymers, then multiple conjugate fiber can be produced, but heat application efficiency becomes critical
Solution Approach 1:
The flow passages are designed with different local characteristics optimized for each polymer type. Each flow passage has dimensions, curvature, and heating surface area specifically suited to the viscosity and melting requirements of the polymer it carries, ensuring efficient heat transfer and melting for each material while maintaining overall system versatility.
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 apparatus enhances production efficiency and reduces costs by allowing the simultaneous spinning of multiple polymers into fibers with improved functions and performance, eliminating the need for a separate intermingling process and facilitating easy maintenance.
Implementation Method 1
an electric heater unit applying heat to the flow passage unit so that high-temperature and high-pressure heat can be efficiently generated with high thermal transfer efficiency
Implementation Method 2
melting polymer materials supplied into hoppers and then extruding and transferring the polymer materials
Implementation Method 3
a gear pump unit comprising a plurality of gear pumps connected to each of the extruders, the gear pumps receiving the polymer materials from the corresponding extruders of the extruding unit and discharging the polymer materials
Implementation Method 4
each of the spinning nozzles receives the multiple kinds of molten polymer materials and spins the polymer materials into a fiber
Data Source
AI summary
A multiple fiber spinning apparatus and a method of controlling the same. The apparatus includes an extruding unit, a spin block unit and a spinning nozzle unit. The extruding unit includes extruders that melt, extrude and transfer polymer materials. The spin block unit includes a gear pump unit which has gear pumps connected to each of the extruders. The gear pumps receive the polymer materials from the corresponding extruders and discharge the polymer materials. The spin block unit further includes a flow passage unit which has flow passages connected to the respective gear pumps. The spinning nozzle unit includes spinning nozzles, each of which is connected to one of the gear pumps of each extruder by the corresponding flow passage, so that each spinning nozzle receives the molten polymer materials and spins the polymer materials into a fiber.