Split Distribution Plates for Fiber Extrusion Alignment
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Solution Overview
Problem
Conventional fiber extrusion packs face limitations in plate-to-plate alignment accuracy, which restricts the density of pattern design and spin hole density due to inherent manufacturing inaccuracies, leading to potential misalignments and increased manufacturing costs.
Innovation Solution
The use of split distribution plates with plate segments and gaps between them, where each segment has its own dowel pin holes for alignment, and reservoirs along the gaps to form sealing plugs, improves plate-to-plate alignment accuracy and prevents polymer leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional single-piece distribution plates are used, then the structure is simple, but the plate-to-plate alignment accuracy is poor leading to misalignment of distribution features
Solution Approach 1:
The distribution plate is divided into multiple plate segments (first plate segment, second plate segment, third plate segment, fourth plate segment) arranged in a stack. Each segment is aligned independently using dowel pins, which reduces the cumulative alignment error compared to a single large plate. The segmentation allows each segment to be manufactured and aligned with higher precision relative to its neighbors.
Solution Approach 2:
Dowel pins are introduced as intermediary alignment elements between adjacent plate segments. The dowel pins fit into corresponding holes in each segment, providing precise mechanical alignment references that ensure the distribution features (channels, holes) across multiple segments align accurately when stacked.
2Area of stationary object
If the plate length is increased to produce wider fiber curtains, then the production capacity increases, but the alignment accuracy decreases due to accumulated manufacturing errors
Solution Approach 1:
The wide distribution plate is segmented into multiple smaller plate segments stacked together. Each segment can be manufactured with high precision independently, and when stacked, they collectively form a wide distribution plate structure. This avoids the cumulative alignment errors that would occur in a single large plate while achieving the desired wide fiber curtain production capacity.
Solution Approach 2:
The solution transitions from a single-plane wide plate to a multi-layer stacked structure. By stacking multiple plate segments in the vertical dimension, the patent achieves wide coverage in the horizontal dimension while maintaining high alignment precision through independent alignment of each layer using dowel pins.
3Ease of manufacture
If plate segments are joined with gaps between them, then manufacturing flexibility increases, but polymer leakage occurs through the gaps
Solution Approach 1:
Sealing plugs are introduced as intermediary elements that fill the gaps between adjacent plate segments. These sealing plugs prevent polymer leakage through the gaps while allowing the plate segments to be manufactured and assembled with flexibility. The sealing plugs act as mediators between the gap structure (which provides manufacturing flexibility) and the polymer flow (which requires sealing).
Data Source
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AI summary
A fiber extrusion pack for extruding molten material to form an array of fibers includes a number of split distribution plates arranged in a stack such that each split distribution plate forms a layer within the fiber extrusion pack, and features on the split distribution plates form a distribution network that delivers the molten material to orifices in the fiber extrusion pack. Each of the split distribution plates includes a set of plate segments with a gap disposed between adjacent plate segments. Adjacent edges of the plate segments are shaped to form reservoirs along the gap, and sealing plugs are disposed in the reservoirs to prevent the molten material from leaking from the gaps. The sealing plugs can be formed by the molten material that leaks into the gap and collects and solidifies in the reservoirs or by placing a plugging material in the reservoirs at pack assembly.