Segmented Distribution Chambers for Uniform Melt Spinning
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Solution Overview
Problem
Existing melt-spinning devices face challenges in producing uniform nonwoven layers over large production widths, as residence time variations in the polymer melt lead to irregularities and differences in physical properties of filament strands, limiting the width of nonwoven layers that can be produced effectively.
Innovation Solution
The device features a spinneret pack with multiple spaced inlet channels and distribution chambers, a perforated plate with angled bores, and filter elements to ensure even melt distribution and constant residence time, allowing for uniform extrusion of filaments across wide production widths by minimizing melt travel distance and maintaining consistent pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single distribution chamber is used to supply the entire width of the nozzle plate, then the structure is simple, but the residence time of the melt varies significantly across the width, leading to irregularities in extrusion and non-uniform physical properties of the filament strands
Solution Approach 1:
The single distribution chamber is divided into multiple distribution chambers (first, second, third, etc.) arranged along the width of the nozzle plate. Each distribution chamber supplies a specific group of nozzle bores, ensuring that the melt travels a relatively short and uniform distance to reach the nozzles within each group. This segmentation eliminates the large residence time variations that occur in a single long distribution chamber, resulting in uniform extrusion conditions and consistent physical properties across all filament strands.
2Productivity
If the production width is increased to exceed 4 meters, then the productivity is improved, but the differences in residence times of the melt in the polymer distribution chamber increase, causing irregularities in extrusion and changed physical properties of the filament strands
Solution Approach 1:
The distribution system is segmented into multiple distribution chambers, each with a limited width, so that even when the overall production width exceeds 4 meters, the melt travel distance within each distribution chamber remains short and uniform. This allows the system to achieve large production widths while maintaining constant residence times and uniform extrusion conditions across all filament strands.
Solution Approach 2:
Each distribution chamber is designed to supply a specific local group of nozzle bores with tailored melt flow characteristics. The local melt distribution in each chamber is optimized for its specific width, ensuring uniform residence times and extrusion conditions locally, which collectively results in uniform quality across the entire wide production width.
3Productivity
If a modular division of the spinneret pack is used to achieve large production widths, then the productivity is improved, but melt differences occur at the extruded groups of filament strands, resulting in different physical properties across the production width
Solution Approach 1:
The spinneret pack is divided into multiple modules, with each module containing a distribution chamber and its associated nozzle bores. This modular segmentation allows for large production widths while maintaining uniform melt residence times within each module. The consistent design and dimensions of each module ensure that all extruded groups of filament strands have the same physical properties, eliminating the non-uniformity that would otherwise occur with modular divisions.
4Device complexity
If the melt has to travel long distances within the nozzle assembly, then a single distribution chamber can cover the entire width, but the residence time of the melt becomes non-constant, leading to irregularities in extrusion
Solution Approach 1:
The distribution chamber is segmented into multiple smaller distribution chambers arranged along the width of the nozzle plate. This segmentation ensures that the melt travels only a short distance within each distribution chamber to reach the associated nozzle bores, maintaining constant residence times. The multiple distribution chambers collectively cover the entire production width, achieving both simple configuration and constant residence time.
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 design enables the production of uniform filaments with consistent physical properties over large production widths, ensuring high-quality nonwovens with minimal variations, and allows for production widths exceeding 5 meters, potentially up to 10 meters by combining spinneret packs.
Implementation Method 1
held in a heated spinning beam
Implementation Method 2
the residence times of the melt in the polymer distribution, which lead to changes in the melt
Implementation Method 3
fed via an inlet channel to an inlet plate and guided into a distributor chamber
Implementation Method 4
the nozzle bores for the extrusion of the filament strands
Implementation Method 5
Immediately before the melt is extruded, the melt streams discharged through the distribution chambers are equalized
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a device for melt spinning of a linear filament bundle with a spinning beam for mounting a longitudinal spinning nozzle group. The spinning nozzle group comprises a nozzle plate on an underside with a number of nozzle drillings and an inlet plate on an upper side with at least one inlet channel, a distribution chamber being arranged between the inlet plate and the nozzle plate, connected to the inlet channel in the inlet plate and the nozzle drillings in the nozzle plate. According to the invention, a residence time for the polymer melt within the nozzle group is kept as constant as possible with a large production range by means of the inlet plate having several residence chambers connected to inlet channels, arranged at a separation from each other in the longitudinal direction of the spinning beam.