Polyester Yarn Cooling and Oiling for Oligomer Control
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Solution Overview
Problem
The production of polyester industrial yarn is hindered by issues such as uneven spinning, high oligomer formation, and heat-related problems during the spinning process, leading to defects like broken fibers, uneven dyeing, and reduced product quality.
Innovation Solution
The method involves using an oil agent containing crown ether, which improves heat resistance and lubricity, and modifying the slow cooling zone by increasing its cross-sectional area and using insulation to maintain spinneret temperature, thereby reducing oligomer deposition and prolonging spinneret cleaning cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active heating is used in the slow cooling zone to maintain temperature, then the spinning temperature can be controlled, but the oligomer coking on the spinneret increases and energy consumption rises
Solution Approach 1:
The patent changes the temperature parameter by using passive heat insulation instead of active heating, maintaining the spinning temperature through thermal retention rather than continuous heat input, thereby reducing oligomer coking
Solution Approach 2:
The patent extracts the heating function from the system by removing active heating devices and relying solely on passive thermal insulation, eliminating the source of excessive heat that causes oligomer coking
2Object-generated harmful factors
If the slow cooling zone temperature is lowered to reduce coking, then oligomer deposition decreases, but the melt flow performance deteriorates and broken fiber increases
Solution Approach 1:
The patent applies preliminary insulation treatment to the slow cooling zone before spinning occurs, pre-retaining heat to ensure melt flow performance without requiring active heating during the process, thus avoiding oligomer deposition
3Ease of operation
If traditional oil agents are used to provide lubricity and antistatic properties, then fiber processing is improved, but heat resistance is insufficient and the oil film breaks at high temperature
Solution Approach 1:
The patent uses a composite oil agent containing crown ether combined with traditional lubricants, creating a material that provides both excellent lubricity for fiber processing and superior heat resistance through the thermal stability of crown ether
Solution Approach 2:
Crown ether acts as an intermediary substance that enhances the thermal stability of the oil film while maintaining its lubricating properties, mediating between the conflicting requirements of processing ease and heat resistance
4Productivity
If the cross-sectional area of the slow cooling chamber is increased to improve cooling efficiency, then oligomer diffusion is enhanced, but the device complexity increases
Solution Approach 1:
The patent increases the cross-sectional area of the slow cooling chamber by expanding in the horizontal dimension rather than increasing height, improving oligomer diffusion without significantly increasing overall device complexity
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 enhances the quality of polyester industrial yarn by improving spinning uniformity, reducing oligomer content, and extending spinneret life, while also reducing energy consumption and improving antistatic and heat resistance properties.
Implementation Method 1
The main component of the spinning oil is surfactant which can form a directional absorption layer, also called oil film, on the surface of chemical fiber. The oil film can reduce the accumulation of the static charge caused by the friction of fibers
Implementation Method 2
using insulation to maintain spinneret temperature
Implementation Method 3
use of oil agent containing crown ether, which improves heat resistance and lubricity
Implementation Method 4
The oil film can reduce the accumulation of the static charge caused by the friction of fibers, thus reduces the surface resistance of the fiber and increases the conductivity of the fiber
Data Source
AI summary
A method for improving the quality of a polyester industrial yarn is provided. First, in the cooling process of preparing a polyester industrial yarn prepared by polyester spinning, the longitudinal height is kept unchanged, and the cross-sectional area of the slow cooling chamber is enlarged. The chamber maintains the surface temperature of the spinneret by means of heat preservation, and then uses an oil agent containing 67.30-85.58 wt % crown ether in the oiling process of polyester industrial yarn prepared by polyester spinning. Enlarging the cross-sectional area of the slow-cooling chamber refers to the cross section of the slow cooling chamber is changed from a circular shape to a rectangular shape while keeping the spinneret connected to the slow cooling chamber unchanged. The cleaning cycle of the spinneret is prolonged by 35-45%, the full package rate of polyester industrial yarn is larger than 99%.