Silicone Yarn Extrusion Vertical Axis Design
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Solution Overview
Problem
Existing plants for producing continuous elastic yarns of silicone material face challenges in maintaining the correct section and uniformity, especially for diameters less than 0.7 mm, due to deformation under extrusion pressure and gravity, and lack precise control and efficient vulcanization processes, which affects the quality and consistency of the final product.
Innovation Solution
A plant design featuring a vertically oriented extrusion axis, a drawing unit to apply a 2-6 fold drawing ratio, and a selectively movable vulcanization oven, allowing for precise control of section and molecular chain orientation, enabling the production of continuous elastic yarns with uniform sections as low as 0.1 mm and preventing deformation and heat-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If horizontal extrusion is used, then the extrusion process is simple, but the extruded product deforms under extrusion pressure and gravity, flattening before entering the vulcanization station
Solution Approach 1:
The patent changes the extrusion direction from horizontal to vertical, utilizing gravity to assist the extrusion process and eliminate the deformation caused by horizontal extrusion pressure. The vertical extrusion axis allows the extruded product to be deposited directly onto the conveyor belt without flattening, maintaining section uniformity throughout the process.
2Ease of operation
If horizontal extrusion is used, then the conveyor belt can transport the extruded product, but the extruded product cannot be held by clamping means and drawn through the vulcanization station
Solution Approach 1:
By orienting the extrusion axis vertically, the extruded product maintains its structural integrity and can be reliably held by clamping means and drawn through the vulcanization station. The vertical orientation prevents the product from flattening or deforming, ensuring consistent handling and processing reliability.
3Adaptability or versatility
If manual movement of the vulcanization oven is used, then the oven can be positioned for different extruded products, but the production process is interrupted and precision positioning is not guaranteed
Solution Approach 1:
The patent implements a movable vulcanization oven that can be dynamically positioned along the vertical extrusion path. This allows the oven to be adjusted for different extruded product types while maintaining continuous production, as the oven movement is integrated into the automated process rather than requiring manual intervention that would interrupt production.
4Manufacturing precision
If extrusion pressure is applied to maintain section, then the extruded product has correct section at the exit, but the section is not uniform over the length of the yarn
Solution Approach 1:
The vertical extrusion orientation allows gravity to act uniformly along the entire length of the extruded product, ensuring consistent section maintenance from the extrusion point through the entire yarn length. This dimensional change eliminates the section variation problem that occurs in horizontal extrusion where pressure distribution is non-uniform.
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 solution ensures continuous yarns with consistent technical-elastic characteristics, precise section control, and reduced deformation, enabling the production of high-quality elastic yarns with uniform sections and improved molecular chain orientation, while allowing for the processing of partially liquid or non-solid silicone rubber.
Implementation Method 1
a drawing unit, located downstream of the vulcanization station and able to impart on the elastic yarn exiting from the extrusion station a drawing value in a ratio comprised between 2 and 6 (100-500%) before vulcanization
Implementation Method 2
an extrusion station, in which the extruded product is made
Implementation Method 3
the extruded product being made is affected both by the extrusion pressure
Implementation Method 4
a vulcanization station located downstream of the extrusion station at a determinate adjustable distance therefrom
Data Source
AI summary
A plant and method for making continuous yarns made of silicone material comprises at least an extrusion station, into which the material is introduced in an amorphous condition, and extrusion means which cause the material to exit from the extrusion station along an extrusion axis. The plant also comprises a vulcanization station, located downstream of the extrusion station, at a determinate distance therefrom, in which the continuous yarn is vulcanized in a direction of treatment. The plant also comprises a drawing unit, disposed downstream of the vulcanization station.