Spunbond Filament Cooling Chamber Segmentation
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Solution Overview
Problem
Existing spunbond web production methods face issues with poor transverse strength and filament diameter inhomogeneities, making it difficult to produce high-fineness or low-titre filaments.
Innovation Solution
An apparatus with a spinneret, cooling chamber divided into two compartments, a monomer suction device, and a stretcher, where process air is managed to achieve specific volumetric flow-rate ratios to cool and stretch filaments, using thermoplastic materials like polypropylene, and employing a deposition device for homogeneous web production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional cooling chamber design is used, then cooling function is provided, but transverse strength of spunbond web is poor
Solution Approach 1:
The cooling chamber is divided into two separate cooling compartments (first cooling compartment and second cooling compartment) with different air flow characteristics. The first cooling compartment provides high-velocity cooling air for initial filament solidification, while the second cooling compartment provides lower-velocity cooling air for controlled cooling. This segmentation allows independent optimization of cooling conditions in different zones, resulting in improved transverse strength without excessive structural complexity.
2Manufacturing precision
If conventional single-compartment cooling chamber is used, then cooling is provided, but filament diameter inhomogeneities occur
Solution Approach 1:
The cooling chamber is segmented into two compartments with different air flow velocities. The first cooling compartment uses high-velocity cooling air (velocity ratio V1/V2 between 0.2-0.5) to achieve rapid and uniform initial cooling, while the second cooling compartment uses lower-velocity air for gradual cooling. This two-stage segmented approach prevents diameter inhomogeneities by controlling the cooling rate distribution along the filament path.
Solution Approach 2:
The invention changes the cooling parameters by introducing two different air flow velocities in sequence. The velocity ratio V1/V2 is controlled within 0.2-0.5, creating optimal cooling conditions at different stages. This parameter change approach ensures uniform filament diameter by preventing premature solidification and diameter variation that occurs in single-compartment designs.
3Manufacturing precision
If high fineness filaments are produced, then filament fineness is improved, but production difficulty increases
Solution Approach 1:
The invention optimizes the cooling air velocity ratio (V1/V2 between 0.2-0.5) and introduces controlled turbulence in the first cooling compartment to enhance heat transfer efficiency. This allows rapid cooling of ultra-fine filaments without excessive diameter variation, making production of filaments with fineness below 1 denier feasible and controllable.
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 enhances the homogeneity and strength of spunbond webs, particularly in the transverse direction, while allowing for the production of filaments with low titres and reduced costs, especially when using specially modified polypropylene.
Implementation Method 1
a cooling chamber into which process air for can be introduced for the purpose of cooling the filaments
Implementation Method 2
a monomer suction device arranged between a spinneret and cooling chamber. The monomer suction device suctions air out from the filament development area directly below the spinneret
Implementation Method 3
the filaments are stretched aerodynamically using the stretcher
Implementation Method 4
a deposition device for depositing the filaments of the spunbond web
Data Source
AI summary
The invention relates to a device for producing a spun-bonded web from filaments, comprising spinnerets, a cooling chamber into which process air can be introduced in order to cool the filaments, a monomer suction device arranged between the spinnerets and the cooling chamber, a stretching unit, and a placing device for placing the filaments so as to form the spun-bonded web. The cooling chamber is divided into two cooling chamber portions. Process air can be suctioned out of a first upper cooling chamber portion to the monomer suction device with a volumetric flow rate Vm, and process air exits the first upper cooling chamber portion into a second lower cooling chamber portion with a volumetric flow rate V1. The volumetric flow rate ratio VM/V1 is 0.1 to 0.3.