Quench Box Duct Segmentation for Yarn Cooling Uniformity
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Solution Overview
Problem
The existing melt spinning device for cooling yarns from a spinning beam results in uneven cooling due to asymmetrical airflow, leading to irregular yarn thickness and quality issues, particularly when cooling tubes are arranged in a staggered manner.
Innovation Solution
The implementation of a yarn cooler with a quench box that supplies cooling wind from both sides through upper and lower connection paths, with varying aperture ratios and orientations of punched plates to ensure even airflow distribution around the cooling tubes, ensuring consistent cooling across all directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If cooling wind is supplied only from the rearward through a duct connected to the trailing end of the cooling tube housing chamber, then the device structure is simple, but the cooling wind distribution becomes uneven with smaller amount reaching front-side cooling tubes, resulting in non-uniform yarn cooling and quality deterioration
Solution Approach 1:
The single duct connection is segmented into multiple connection ports (first connection port at the rearward side and second connection port at the forward side) distributed along the cooling tube housing chamber. This segmentation allows cooling wind to be supplied from multiple locations, ensuring uniform distribution to all cooling tubes while maintaining structural simplicity.
Solution Approach 2:
The duct connection is extended from a single-point connection to a multi-point distribution system along the length of the cooling tube housing chamber. By adding connection ports at different positions (rearward and forward sides) and using multiple connection paths, the system achieves uniform cooling wind distribution without significantly increasing structural complexity.
2Area of stationary object
If cooling tubes are arranged in a staggered manner to optimize space utilization, then the device compactness is improved, but the cooling wind distribution becomes increasingly uneven particularly affecting front-side cooling tubes
Solution Approach 1:
The cooling tube housing chamber is divided into multiple sections with connection ports distributed along its length. This segmentation ensures that cooling wind reaches both rearward and forward cooling tubes effectively, even when arranged in a compact staggered pattern, thereby maintaining uniform cooling across the entire chamber.
Solution Approach 2:
The connection system transitions from a single rearward connection to a distributed multi-dimensional connection network with ports at both rearward and forward sides. This allows cooling wind to penetrate the staggered arrangement uniformly from multiple directions, solving the distribution problem while maintaining compact footprint.
3Device complexity
If the duct is positioned on one side of the cooling tube housing chamber, then the device structure is simplified, but the cooling wind flow path creates asymmetrical distribution with insufficient cooling at distant cooling tubes
Solution Approach 1:
The single-sided duct connection is segmented into multiple connection ports positioned at different locations (rearward and forward sides) along the cooling tube housing chamber. This segmentation creates multiple shorter flow paths, ensuring efficient cooling wind delivery to all cooling tubes including those at distant positions, thereby maintaining high cooling efficiency without complex duct configuration.
Solution Approach 2:
The duct system evolves from a single-point connection to a distributed connection network extending along the chamber length. This multi-dimensional arrangement of connection ports creates balanced flow paths to all cooling tubes, maximizing cooling efficiency while keeping the duct configuration relatively simple.
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 configuration ensures that yarns are evenly cooled from all directions, improving yarn quality by maintaining consistent thickness and enhancing the cooling efficiency immediately after spinning.
Implementation Method 1
The cooling wind supplied from the duct is rectified by filters constituting the cooling tubes, and is then blown into spaces (yarn running spaces) which are formed inside the cooling tubes
Implementation Method 2
The cooling wind supplied from the duct is rectified by filters constituting the cooling tubes
Implementation Method 3
This cooling wind cools the yarns running in the yarn running spaces
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Inside a quench box 22 are formed a cooling tube housing chamber 41, an upper connection path 42, and a lower connection path 43. The cooling tube housing chamber 41 houses therein a plurality of cooling tubes 21 to oppose spinnerets 13 of a spinning beam 2, and these cooling tubes 21 are arranged to form two rows in the crosswise direction in a staggered manner. The cooling tube housing chamber 41 has, at the lower end portions of wall surfaces 41a and 41b, a first connection port 45 and a second connection port 46. The first connection port 45 is connected to an upper connection path 42 which is connected to a duct 60 and extends in the crosswise direction. The second connection port 46 is connected to a lower connection path 43 which is provided below the upper connection path 42, is connected to the duct 60, and extends along the lower part of the cooling tube housing chamber 41.