Spinning Pack Nozzle Heating for Yarn Molecular Alignment

Solution Overview

Problem

The existing methods for manufacturing high-strength polyester yarns face challenges in achieving a balance between draw ratio and degree of orientation, leading to suboptimal mechanical properties due to the trade-off relationship between these factors, and the high cost and complexity of laser heating for uniform molecular alignment.

Innovation Solution

A spinning pack with a protruding nozzle unit and a heating unit that heats the nozzle to 400-600°C, allowing for uniform molecular alignment of filaments while controlling temperature effectively, thereby improving the physical properties of the yarn without affecting other components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If laser heating is used to heat filaments directly under the spinneret nozzle, then molecular alignment is improved, but manufacturing cost and device complexity increase significantly

Engineering Contradiction:

Improvemolecular alignmentVSAvoiddevice complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent replaces the complex laser heating system with a simple thermal conduction heating system. Instead of using laser beams to heat the spinneret nozzle, the invention uses a heating unit that conducts heat through the spinneret body, which is a much simpler and more cost-effective approach achieving the same molecular alignment effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs an inexpensive heating unit that can be easily replaced or adjusted, rather than investing in expensive laser heating equipment. This heating unit provides sufficient thermal energy for molecular alignment without the high cost and complexity of laser systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Stability of the object's composition

If laser heating is used to heat filaments directly under the spinneret nozzle, then molecular alignment is improved, but manufacturing cost increases

Engineering Contradiction:

Improvemolecular alignmentVSAvoidmanufacturing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent employs an inexpensive heating unit that can be easily replaced or adjusted, rather than investing in expensive laser heating equipment. This heating unit provides sufficient thermal energy for molecular alignment without the high cost and complexity of laser systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces the complex laser heating system with a simple thermal conduction heating system. Instead of using laser beams to heat the spinneret nozzle, the invention uses a heating unit that conducts heat through the spinneret body, which is a much simpler and more cost-effective approach achieving the same molecular alignment effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If heating unit is integrated into the spinneret structure, then temperature control is effective, but ease of repair and maintenance decrease

Engineering Contradiction:

Improvetemperature controlVSAvoidease of repair

Core Design Contradiction:

TemperatureVSEase of repair

Solution Approach 1:

The patent divides the heating system into a separate heating unit and the spinneret nozzle. This segmentation allows the heating unit to be independently controlled for effective temperature management while enabling easy removal, replacement, or maintenance of either component without affecting the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating unit is extracted from the spinneret structure and positioned separately. This extraction maintains effective temperature control through thermal conduction while significantly improving ease of repair and maintenance, as the heating unit can be accessed and serviced independently of the spinneret.

Inventive Principle:

Principle #2Taking out (Extraction)

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 enables the production of yarns with enhanced tensile strength and reproducibility, achieving a tensile strength of 8.5 g/d or more and a strength retention rate of 88% or more in tire cords, while reducing manufacturing costs and simplifying the installation and removal of the heating unit.

Implementation Method 1

a heating unit for heating the nozzle unit

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS11603604B2Spinning pack for manufacturing high strength yarn, and yarn manufacturing apparatus and method

Publication Date: 2023.03.14 KOLON INDUSTRIES INC

AI summary

One embodiment of the present disclosure provides a spinning pack, a yarn manufacturing apparatus including the spinning pack, a yarn manufacturing method using the yarn manufacturing apparatus, and yarn manufactured by the manufacturing method. The spinning pack includes a spinneret having a nozzle unit, a heating unit for heating the nozzle unit, a pack body surrounding at least a part of the spinneret, and a spinning block surrounding the pack body, wherein the spinneret includes a first surface which defines a storage space while facing at least one surface of the spinning block, and a second surface facing the first surface, wherein the nozzle unit includes a plurality of discharge holes and protrudes from the second surface; and wherein the heating unit is disposed at the outer side of the nozzle unit.