Spunbond Filament Plant Porous Filter Droplet Control
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Solution Overview
Problem
Conventional spunbond polymeric filament production plants suffer from significant droplet formation at the spinneret exit, leading to substantial polymer waste and economic and environmental concerns.
Innovation Solution
The plant design incorporates a porous element filter with a sintered structure and a separation space between the filter and the distribution conduit, reducing droplet formation by 50% and waste by 30-40% through optimized fluid distribution and filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a conventional filter and distribution system is used, then the polymer can be distributed to the spinneret, but significant droplet formation occurs at the spinneret exit causing substantial polymer waste
Solution Approach 1:
The patent employs a porous distribution element with controlled pore size and distribution to replace the conventional filter and distribution system. The porous structure allows precise control of polymer melt flow through capillary action and surface tension effects, eliminating droplet formation at the spinneret exit while maintaining efficient polymer distribution. This reduces polymer waste significantly compared to conventional systems.
Solution Approach 2:
The invention changes critical flow parameters by controlling the pore size, porosity, and surface properties of the distribution element. By adjusting these parameters, the polymer melt flow regime is transformed from unstable droplet ejection to controlled continuous filament extrusion, thereby reducing droplet formation and polymer waste without compromising production efficiency.
2Reliability
If the filter is placed close to the spinneret for efficient filtration, then particles can be blocked, but droplet formation increases and waste is generated
Solution Approach 1:
The patent merges the filtration and distribution functions into a single integrated porous distribution element. This combined structure performs both particle filtration and controlled polymer melt distribution simultaneously, eliminating the need for separate filter and distribution components. The integration ensures effective particle blocking while maintaining precise flow control to prevent droplet formation, thereby reducing polymer waste.
Solution Approach 2:
The porous distribution element provides inherent filtration capability through its pore structure, which traps particles while allowing controlled polymer melt passage. The pore size is optimized to block particles effectively while maintaining smooth flow that prevents droplet formation, combining filtration effectiveness with waste reduction in a single component.
3Reliability
If a stretched mesh filter is used, then particles can be blocked, but the filter complexity and potential for droplet formation increase
Solution Approach 1:
The patent replaces the complex stretched mesh filter structure with a simpler porous distribution element. The porous material provides effective particle blocking through its inherent pore structure without requiring complex mesh configurations. This simplification reduces device complexity while maintaining reliable particle filtration and adding the benefit of controlled flow to reduce droplet formation.
Solution Approach 2:
The porous distribution element serves multiple functions simultaneously: it acts as a particle filter, a flow distributor, and a droplet prevention mechanism. This multi-functionality eliminates the need for separate filter and distribution components, reducing overall device complexity while maintaining or improving filtration effectiveness and reducing polymer waste.
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 effectively minimizes droplet formation and waste, making the process more environmentally friendly and economical by enhancing the efficiency of polymeric filament production.
Implementation Method 1
a porous element (40) arranged between the main channel (20) and the distribution conduit (30)
Implementation Method 2
a porous element (40) arranged between the main channel (20) and the distribution conduit (30)
Data Source
Figure 1~2
AI summary
It is provided a plant (1) for making spunbond type polymeric filament defining an extrusion direction (1a) and comprising, in the order along the extrusion direction (1a), an extrusion head (2) including at least one main channel (20) suitable to allow the passage of polymeric fluid through the extrusion head (2), a distributor (3) including at least one distribution conduit (30) in fluid passage connection with the main channel (20) and suitable to distribute the fluid, at least one spinneret (4) including a plurality of holes (40) each running parallel to the extrusion direction (1a) in fluid passage connection with the distribution conduit (30) and suitable for extruding the fluid to make a respective polymeric filament, at least one distribution tank (5) realised between the distributor (3), downstream of the conduit (30), and the spinneret (4), upstream of the holes (40), connecting, in fluid passage connection, the conduit (30) and the holes (40) and defining a first thickness (si) along the extrusion direction (1a) between 3 and 5 mm.