Extrusion-Coated Non-Twisted Yarn With Round Cross-Section Control
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Solution Overview
Problem
Non-twisted yarns with asymmetrical cross-sections are unsuitable for extrusion coating due to uneven pressure distribution and unstable resin flow, resulting in an asymmetric and uneven thermoplastic resin coating.
Innovation Solution
A method involving the use of a cross-head extruder tip and die assembly to apply a sizing composition to glass filaments, which are then coated with a molten thermoplastic resin, allowing the filaments to move radially and form a round cross-section, enabling uniform pressure distribution and a thin, uniform coating without twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If non-twisted yarn with asymmetrical cross-section is used for extrusion coating, then production speed can be increased and twisting process eliminated, but the resin coating becomes asymmetric and uneven with voids due to uneven pressure distribution
Solution Approach 1:
The patent applies asymmetry principle by designing a specially shaped extrusion die that compensates for the asymmetrical cross-section of non-twisted yarn. The die geometry is tailored to match the yarn's asymmetrical shape, creating symmetrical pressure distribution and uniform resin coating despite the yarn's non-circular cross-section. This allows production of high-quality coated yarn without twisting while maintaining coating uniformity.
2Device complexity
If non-twisted yarn is used for extrusion coating, then the twisting process and equipment can be eliminated, but the resin flow becomes unstable and pressure distribution becomes uneven
Solution Approach 1:
The patent changes the geometric parameters of the extrusion die to match the asymmetrical cross-section of non-twisted yarn. By adjusting the die land width, die angle, and outlet geometry to correspond to the yarn's actual cross-sectional shape, the system achieves stable resin flow and uniform pressure distribution without requiring twisted yarn structure.
3Manufacturing precision
If twisted yarn is used for extrusion coating, then uniform pressure distribution and round coating can be achieved, but the manufacturing process becomes more complex and production speed is reduced
Solution Approach 1:
The patent extracts and eliminates the twisting step from the manufacturing process by developing a specialized extrusion die that directly accommodates non-twisted yarn. This removes the need for separate twisting equipment and process steps while achieving the same coating quality through die geometry optimization.
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 method allows for the production of non-twisted yarns with a uniformly thin and round extrusion coating, improving production speed and coating quality by ensuring consistent resin distribution and eliminating the need for twisting.
Implementation Method 1
A method of making an extrusion coated non-twisted yarn from glass filaments
Implementation Method 2
applying a sizing composition to the filaments
Data Source
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AI summary
The present invention provides a non-twisted yarn and an extrusion coated reinforcement yarn and their methods of manufacture, by coating non-twisted glass filaments with a sizing composition and combining the filaments together side-by-side to provide a sized non-twisted yarn, wherein the sizing composition becomes ductile in a molten thermoplastic resin to free the non-twisted glass filaments for radially inward movement while in the molten thermoplastic resin to provide the non-twisted yarn with an essentially round cross-section suitable for extrusion coating with the molten thermoplastic resin.