Patterned Spinneret TPEE Yarn Structure for High-Denier Weaving
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current fiber manufacturing methods, such as dry spinning and melt spinning, face challenges in producing high-denier yarn with uniform quality due to solvent use and bonding issues, leading to environmental concerns and yarn slippage during weaving.
Innovation Solution
A method for manufacturing thermoplastic polyester elastomer yarn using a melt spinning process with a patterned spinneret having a merging-yarn area and symmetrically distributed pseudo-yarn areas, which are in communication, to form an integrally structured yarn without additional bonding steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dry spinning is used to manufacture fibers, then fine polymer filaments can be formed, but a large amount of solvent is required which raises environmental concerns
Solution Approach 1:
The patent changes the manufacturing parameter from dry spinning to melt spinning, fundamentally altering the process to eliminate solvent usage while maintaining the ability to form fine polymer filaments through controlled melting and extrusion of the polymer material
2Quantity of substance
If multiple yarn strands are combined through friction bonding or air pressure to form plied yarn, then higher denier yarn can be obtained, but significant variation in appearance occurs leading to uneven quality
Solution Approach 1:
The spinneret is divided into multiple independent holes, each forming a separate yarn strand that is then automatically combined into a unified plied yarn structure, allowing controlled multiplication of strands while maintaining uniformity through the systematic arrangement of segments
Solution Approach 2:
Multiple yarn strands formed through the multiple holes of the spinneret are automatically merged into a single plied yarn structure through the merging-yarn area, eliminating the need for separate bonding operations and ensuring uniform appearance across all strands
3Quantity of substance
If melt spinning is used to manufacture higher denier yarn, then higher denier yarn can be produced, but the yarn tends to slip off the yarn cake and break during weaving due to insufficient contact area and friction
Solution Approach 1:
The spinneret holes are designed with a three-dimensional patterned structure including protruding pseudo-yarn areas and merging-yarn areas, adding geometric complexity to the yarn cross-section to increase surface area and contact area without changing the basic melt spinning process
Solution Approach 2:
The yarn structure is designed with different local regions having different properties: the merging-yarn area provides cohesion and friction, while the pseudo-yarn areas provide surface area and texture, creating optimal local characteristics for preventing slippage during weaving
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 produces high-denier yarn with enhanced surface area and reduced slippage, ensuring uniform quality and stability during weaving processes.
Implementation Method 1
conducting a melt spinning process by using the thermoplastic polyester elastomer to produce the thermoplastic polyester elastomer yarn
Data Source
AI summary
A thermoplastic polyester elastomer yarn and a method for manufacturing the same are provided. The method for manufacturing the thermoplastic polyester elastomer yarn includes: providing a thermoplastic polyester elastomer; and performing a melt spinning process by using the thermoplastic polyester elastomer to produce the thermoplastic polyester elastomer yarn. The thermoplastic polyester elastomer includes s 50% to 70% by weight of a soft segment and 30% to 50% by weight of a hard segment, and the intrinsic viscosity of the thermoplastic polyester elastomer is between 1.1 dL/g and 1.6 dL/g. The spinneret used in the melt spinning process is formed with patterned spinneret holes, which include a merging-yarn area and a plurality of pseudo-yarn areas. The pseudo-yarn areas are symmetrically distributed around the merging-yarn area, and each pseudo-yarn area is in communication with the merging-yarn area. The number of pseudo-yarn areas is three or more.