Full-Dull Polyester Fiber Texturing With Rolling Yarn Guides
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Solution Overview
Problem
The use of inorganic matting agents in polyester fibers leads to rapid wear of yarn guides, resulting in network derailment, poor interlacing, and uneven fabric quality due to increased tension and sliding friction during the DTY texturing process.
Innovation Solution
Replace traditional yarn guides with fixed pulley yarn guide wheels, adjust the inferior angle of the tow to 140°-160°, and implement a linear velocity ratio of 1.05-1.06 between rollers to convert sliding friction to rolling friction, ensuring stable tow tension and interlacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If inorganic matting agents (titanium dioxide) are added to polyester fibers to reduce gloss intensity and achieve cotton-like effect, then the fiber surface smoothness is reduced and gloss is diffused, but the yarn guides experience rapid wear and network derailment occurs
Solution Approach 1:
The patent extracts and removes the inorganic matting agents (titanium dioxide) from the polyester fiber production process. Instead of adding external matting agents, the invention uses fully drawn yarn (FDY) with inherent surface characteristics that provide the desired cotton-like effect without compromising yarn guide durability. This extraction eliminates the source of the wear problem while maintaining the optical properties.
Solution Approach 2:
The patent replaces the durable but problematic inorganic matting agents with a process-oriented solution using FDY that achieves the same optical effect without the harmful side effects. The FDY serves as a temporary processing intermediate that provides the necessary surface characteristics during texturing, then is consumed in the process to create the final DTY product without leaving residual harmful substances.
2Illumination intensity
If inorganic matting agents are added to achieve full-dull cotton-like effect, then the fiber surface becomes rougher for diffuse reflection, but the tension increases causing network derailment and poor interlacing
Solution Approach 1:
The patent removes the inorganic matting agents that were causing excessive tension and network derailment. By using FDY with appropriate surface characteristics instead of adding titanium dioxide, the invention achieves gloss diffusion through the inherent properties of the drawn yarn rather than through abrasive inorganic additives that increase friction and tension.
Solution Approach 2:
The patent changes the physical and chemical parameters of the fiber by using fully drawn yarn (FDY) as the starting material instead of pre-oriented yarn (POY). The FDY has different surface smoothness, crystallinity, and mechanical properties that enable gloss diffusion without requiring inorganic additives. This parameter change eliminates the need for matting agents and their associated tension problems.
3Illumination intensity
If traditional yarn guides are used with inorganic matting agents, then the cotton-like effect is achieved, but the yarn guides wear out within 3-5 days requiring frequent replacement
Solution Approach 1:
The patent extracts and eliminates the inorganic matting agents (titanium dioxide) that cause rapid wear of yarn guides. By using FDY with inherent surface characteristics to achieve the cotton-like effect, the invention removes the abrasive substances that degrade the yarn guides, extending their service life from 3-5 days to much longer periods.
Solution Approach 2:
The patent introduces fully drawn yarn (FDY) as an intermediary material that provides the desired surface characteristics for gloss diffusion without the harmful effects of inorganic additives. The FDY acts as a mediator between the requirement for cotton-like appearance and the need to protect yarn guides from wear, transferring the functional requirement without the harmful side effects.
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
Reduces yarn guide wear, stabilizes tow tension, and improves interlacing, resulting in smoother, less breakable fabrics with consistent quality over extended production periods.
Implementation Method 1
Replace traditional yarn guides with fixed pulley yarn guide wheels, adjust the inferior angle of the tow to 140°-160°, and implement a linear velocity ratio of 1.05-1.06 between rollers to convert sliding friction to rolling friction
Data Source
AI summary
A method for preparing full-dull cotton-like polyester fibers includes: sequentially passing a full-dull polyester POY fiber and a full-dull polyester FDY fiber through a first yarn guide, a yarn guide tube, a second yarn guide, a first yarn feeding roller, pre-entangling, a second yarn feeding roller, a first deformation hot box, a cooling plate, a false twister, a third yarn feeding roller, a middle entangling device, a setting hot box, a setting yarn feeding roller, oiling, and DTY winding and forming to obtain the same. The first and second yarn guides are both yarn guide wheels; a tow is wound around the first yarn feeding roller for 2-3 turns; an inferior angle of the tow before and after contacting a groove bottom of the second yarn guide is 140°-160°; a linear velocity ratio of the first yarn feeding roller to the second yarn feeding roller is 1.05-1.06.