Systems and methods for manufacturing colored product
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Solution Overview
Problem
The existing methods for producing colored yarn are inefficient in changing colors, resulting in significant material waste and time consumption due to the need to completely purge colored resin from the main extruder during color changes.
Innovation Solution
A system comprising a primary polymer melt source and a side arm extruder assembly that injects a colored polymer melt concentrate into a transfer line, allowing for efficient color changes by purging the old color and introducing a new color without fully stopping the extruder and melt pump, thereby reducing waste and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the main extruder is completely purged during color change, then color purity is improved, but material waste increases and time consumption increases
Solution Approach 1:
The system divides the extrusion system into two independent segments: the main extruder that processes bulk polymer and the side arm extruder that handles color concentrate. This segmentation allows the side arm to be purged independently with minimal impact on the main extruder, reducing overall material waste while maintaining color purity in the final product.
Solution Approach 2:
The side arm extruder acts as an intermediary device between the main extruder and the product forming device. It introduces color concentrate into the polymer melt stream without requiring the main extruder to be stopped or completely purged, thereby maintaining continuous production while achieving color change.
2Manufacturing precision
If the main extruder is completely purged during color change, then color purity is improved, but production time increases
Solution Approach 1:
By segmenting the color introduction function into a separate side arm extruder, the main extruder can continue operating without interruption. The side arm undergoes rapid purging independent of the main extruder cycle, significantly reducing the overall color change time while ensuring color purity through the side arm's independent purging mechanism.
Solution Approach 2:
The side arm extruder performs preliminary color concentration preparation and can be purged in advance before the actual color change is needed in the main product stream. This preliminary action allows for faster color transitions without compromising the quality of the final product.
3Manufacturing precision
If the extruder and melt pump are stopped during color change, then color control is improved, but productivity decreases
Solution Approach 1:
The side arm extruder serves as an intermediary that handles all color change operations while the main extruder and melt pump continue running at full capacity. This allows color control to be achieved through the side arm's regulated concentrate injection without interrupting the main production flow, thereby maintaining high productivity.
Solution Approach 2:
The system maintains continuous operation of the main extruder and melt pump throughout the color change process. The side arm extruder manages the color transition while the primary production system operates without interruption, ensuring continuous useful action and maximizing productivity.
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 enables rapid and efficient color changes, minimizing material waste and time required for color transitions, with color changes achieved in under 20 minutes, and maintaining color specifications within a short timeframe.
Implementation Method 1
The side arm extruder assembly can comprise an outlet positioned within the transfer line to inject a colored polymer melt concentrate into the transfer line
Data Source
AI summary
A system for making polymeric fibers can comprise a main extruder configured to receive a polymer feedstock composition. The main extruder can have an outlet in fluid communication with a transfer line configured to receive a polymer melt from the main extruder and transfer the polymer melt in a flow direction that is towards a spinneret. A side arm extruder assembly can be positioned along the transfer line between the main extruder and the spinneret. The side arm extruder assembly can comprise an outlet positioned within the transfer line to inject a colored polymer melt concentrate into the transfer line.