A method of processing synthetic fibers, synthetic fibers, a method of spinning synthetic fibers and spun yarn

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Solution Overview

Problem

High-speed spinning of synthetic fibers leads to scum accumulation on spinning machine components, reducing operational performance and potentially damaging fibers, especially in whirling air spinning, where high speeds exacerbate this issue.

Innovation Solution

The method involves adding a processing agent containing an organophosphate metal salt between spinning and crimping and a lubricant-containing agent after crimping up to carding, specifically using Processing Agent A with 40-80% organophosphate metal salt and 20-60% nonionic surfactant, and Processing Agent B with 20-90% lubricant and 10-80% dispersing agent, applied through methods like spraying or roller oiling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If spinning speed is increased to improve productivity, then production cost is reduced and productivity is improved, but scum accumulation on spinning machine components increases and cleaning interval shortens

Engineering Contradiction:

Improvespinning speedVSAvoidscum accumulation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent applies processing agents containing organophosphate metal salts and lubricants to synthetic fibers before high-speed spinning. This preliminary treatment prevents scum accumulation from occurring in the first place during high-speed spinning operations, allowing sustained high productivity without the harmful effects of scum buildup on machine components

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces processing agents containing organophosphate metal salts and lubricants as intermediary substances between the fibers and spinning machine components. These agents act as mediators that reduce direct contact and friction between fibers and machine surfaces, preventing scum accumulation while maintaining high spinning speeds

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If spinning speed is increased to improve productivity, then production cost is reduced, but operational performance deteriorates due to scum accumulation

Engineering Contradiction:

Improvespinning speedVSAvoidoperational performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The processing agents are applied to fibers before spinning to preemptively protect against operational performance deterioration. This preliminary protection ensures that even at high spinning speeds, the machine components remain free from scum accumulation that would otherwise degrade operational reliability

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If conventional processing agents containing alkyl phosphate potassium salts are used, then fibers can be processed, but scum accumulation occurs at the antinode ring, inside the rotor, and around the spindle

Engineering Contradiction:

Improvefiber processing capabilityVSAvoidscum accumulation

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the processing agent by replacing conventional alkyl phosphate potassium salts with organophosphate metal salts containing specific functional groups. This parameter change in the chemical structure fundamentally alters the interaction between the processing agent and machine components, eliminating scum accumulation while maintaining fiber processing capability

Inventive Principle:

Principle #35Parameter changes

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

This approach effectively suppresses scum accumulation, enhancing high-speed spinning capabilities and maintaining fiber quality by preventing damage and breakage, as demonstrated in high-speed ring, rotor-type open-end, and whirling air spinning processes.

Implementation Method 1

a processing agent containing an organophosphate metal salt is added to the synthetic fibers in a process between spinning and crimping

Methodology Applied

Scientific EffectLubrication: Lubrication

Implementation Method 2

a processing agent containing a lubricant is added in a process after crimping up to carding

Methodology Applied

Scientific EffectLubrication: Lubrication

Data Source

PatentEP2735644B1A method of processing synthetic fibers, synthetic fibers, a method of spinning synthetic fibers and spun yarn

Publication Date: 2017.01.04 TAKEMOTO OIL & FAT CO LTD

AI summary

The present invention supplies a method of processing synthetic fibers that can suppress scum accumulation substantially in the high-speed spinning of synthetic fibers and give good high-speed spinning capabilities to the synthetic fibers; the synthetic fibers obtained with said processing method; a method of spinning said synthetic fibers; and a spun yarn obtained with said method of spinning. In the high-speed spinning of synthetic fibers, the processing agent containing an organophosphate metal salt is applied to the synthetic fibers in a specific process in the upstream and, further, the processing agent containing a lubricant is applied in a specific process in the midstream.