Single-Roller Finish Application After Drying to Reduce Material Loss
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Solution Overview
Problem
Current finish application methods in acrylic fiber production result in finish loss during drying, inefficiencies in finish distribution, high capital costs, energy consumption, labor-intensive processes, and material wastage due to the use of multiple rollers and complex systems, leading to suboptimal fiber processing and quality issues.
Innovation Solution
A single ceramic-coated feeding roller system with a circulation mechanism that applies finish to the tow band after drying, utilizing a finish with high surface tension and a gluey structure to ensure uniform coverage, while recirculating excess finish and filtering out impurities, thereby reducing finish usage and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the finish is applied by immersing the tow band in a finish bath before drying rollers, then the fiber surface is covered with finish, but significant finish loss occurs during the drying process
Solution Approach 1:
The finish is applied to the tow band after drying rather than before, eliminating the harmful drying process that causes finish loss. This reverses the conventional sequence of operations to prevent the problem at its source.
Solution Approach 2:
The drying process that previously caused finish loss is repositioned to occur before finish application. The heat and airflow from drying are now beneficial for preparing the fiber surface to receive and retain finish more effectively, converting a harmful process into a beneficial one.
2Manufacturing precision
If multiple rollers are used in the finish application system, then finish can be applied to both surfaces of the tow band, but the system complexity and capital cost increase
Solution Approach 1:
Multiple finish pools and rollers are merged into a single integrated pool and roller system. The single ceramic-coated roller performs the function of multiple rollers by effectively distributing finish across the tow band surface through its rotation and contact mechanism.
Solution Approach 2:
The single ceramic-coated roller serves multiple functions: it applies finish to the tow band surface, distributes the finish uniformly, and the ceramic coating provides both finish retention and release properties. This multi-functional design eliminates the need for multiple specialized rollers and pools.
3Ease of operation
If the idle roller rotates at the same linear velocity as the tow band (100-150 m/min), then the roller can be driven by the tow band, but the finish cannot be applied in desired quantity and homogeneity
Solution Approach 1:
The linear velocity parameter of the roller is changed from matching the tow band speed (100-150 m/min) to a lower speed. This speed differential allows the roller to effectively deposit finish onto the moving tow band, creating the necessary conditions for homogeneous finish application while maintaining ease of operation through passive roller drive.
Solution Approach 2:
Instead of the roller rotating at the same speed as the tow band to be driven passively, the system inverts the speed relationship: the roller rotates slower than the tow band, allowing the tow band to drag the roller along while still enabling effective finish transfer. This inversion of the speed relationship solves the homogeneity problem.
4Quantity of substance
If more than one finish pool is used to apply finish to the tow band, then both surfaces can be covered, but material consumption increases due to excess finish absorption
Solution Approach 1:
Multiple finish pools are merged into a single pool system, eliminating redundant finish storage and application points. This consolidation reduces the total amount of finish material required while still achieving complete coverage of both tow band surfaces through the single roller's rotational action.
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 system achieves 25-30% finish savings, prevents finish loss during drying, ensures homogeneous application, reduces capital and operational costs, and simplifies the process, enabling easier activation and maintenance with minimal labor, while maintaining fiber quality.
Implementation Method 1
utilizing a finish with high surface tension and a gluey structure to ensure uniform coverage
Implementation Method 2
at least one circulation pump (4) which enables the finish coming from the finish feeding tank (2) to be transferred to the finish feeding tray (5)
Implementation Method 3
at least one feeding tank filter (3) which enables the finish overflowing from the finish feeding tray (5) to be cleaned before being transferred to the finish feeding tank (2) again
Data Source
AI summary
The present invention relates to a finish application system (10) which enables homogenous dispersion by the finish being applied on the fiber differently. With the invention, finish loss during drying is prevented, a finish application is realized which creates the same effect with the known systems by using less finish, enables energy saving, has low first capital cost, is easy to be activated in first operation and after the system being stopped, enables less labor and effort to be spent.