Spinning Pack Kneading Part for Polymer Viscosity Uniformity
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Solution Overview
Problem
Existing spinning packs fail to uniformly knead thermoplastic polymers due to thermal history differences between inner and outer layers, leading to viscosity unevenness and quality differences in spun filaments, especially for high viscosity polymers in laminar flow states.
Innovation Solution
A spinning pack with a kneading part comprising an introduction plate, supply plate, and converging plate, divided into virtual regions with strategically positioned introduction and supply holes, and converging grooves to repeatedly converge and distribute the polymer, ensuring thorough kneading and minimizing thermal history differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the pack for spinning is heated at high temperature in the heating box, then the polymer is maintained in a melted state, but temperature difference occurs between inner and outer layers causing viscosity unevenness
Solution Approach 1:
The pack for spinning is divided into multiple heating zones along the polymer flow path, with each zone independently controllable. This segmentation allows different temperature profiles in different regions, preventing thermal stratification and ensuring uniform viscosity throughout the polymer melt by addressing the temperature distribution issue zone by zone rather than as a single uniform heating space
Solution Approach 2:
Different regions of the pack for spinning are provided with different heating conditions - the inner layer regions receive different thermal input compared to outer layer regions. This local differentiation of heating quality compensates for the natural temperature gradient, ensuring that polymers in different positions experience equivalent thermal history and achieve uniform viscosity
2Device complexity
If conventional mixing structures are used, then the device complexity is low, but the kneading effect is insufficient especially for high viscosity polymers
Solution Approach 1:
The pack for spinning incorporates a rotating mixing element that actively stirs the polymer melt during processing. This dynamic mixing mechanism creates turbulent flow and repeated folding of the polymer stream, significantly enhancing the kneading effect for high viscosity polymers compared to static mixing structures, while the rotation speed can be adjusted to optimize mixing intensity
Solution Approach 2:
The mixing mechanism extends mixing action from a single plane to three-dimensional space through the rotating element that sweeps through the polymer melt volume. This multi-dimensional mixing approach ensures thorough homogenization of polymers from different thermal history zones, achieving uniform viscosity throughout the entire melt volume rather than just at specific locations
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 achieves uniform viscosity and quality among filaments by enhancing the kneading effect, reducing thermal history differences and physical property variations, resulting in high-quality fibers with minimal thermal deterioration.
Implementation Method 1
The pack for spinning is usually placed in a heating box in order to maintain the melted state of the polymer and heated at high temperature
Implementation Method 2
the temperature of the inner layer part is lower than that of the outer layer part, which is in contact with the heating box, of the pack for spinning and temperature difference occurs
Implementation Method 3
the introduced polymer is passed through a filter medium and filter disposed in the pack for spinning to remove foreign matters existing in the polymer and distributed by a porous plate
Implementation Method 4
The distributed polymer is spun from the discharge holes of a spinneret
Data Source
AI summary
A pack for spinning is provided with a kneading part disposed on a spinneret. The kneading part includes: an introduction plate including a plurality of first introduction holes for introducing a melted polymer; and a plurality of kneading units including a supply plate including a plurality of independent supply grooves into which the polymer introduced from the introduction holes flows and one or more supply holes disposed in each of the supply grooves, and a converging plate including a plurality of converging grooves in which a plurality of grooves into which the polymer supplied from the supply holes flows are intersected and a plurality of second introduction holes disposed in each of the converging grooves.