Tapered Roller Drawing Device for Synthetic Fibers
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Solution Overview
Problem
Conventional drawing devices are limited to two to four stages due to size and cost constraints, making it difficult to achieve high draw ratios for synthetic fibers like polyester and polyamide, which require multi-stage drawing to enhance strength and dimensional stability.
Innovation Solution
A compact drawing device using a pair of tapered rollers with controlled taper ratios and heating zones, allowing for multiple stages of drawing by repeatedly spanning the rollers with the drawable material, enabling high draw ratios without the need for large facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drawing devices with multiple heating rollers are used to increase draw ratio, then the draw ratio can be increased, but the facility size and complexity increase significantly
Solution Approach 1:
The patent combines multiple drawing functions into a single tapered roller by creating a velocity gradient across its surface. Different radial positions on the roller surface provide different linear velocities, enabling multiple drawing stages to occur simultaneously within one compact component rather than requiring multiple separate heating rollers and drawing stations.
Solution Approach 2:
The invention introduces a radial dimension to the drawing process by utilizing the velocity gradient across the roller surface radius. The linear velocity varies with radial distance from the center, allowing different drawing ratios to be achieved at different radial positions, thereby compacting multiple drawing stages into a single rotational element.
2Device complexity
If conventional drawing devices are used, then the device structure is simple, but the maximum draw ratio is limited to 1.7-2.4 times
Solution Approach 1:
The patent applies dynamics by creating a non-uniform velocity distribution across the roller surface through its tapered geometry. The rotational motion combined with the varying radius produces different linear velocities at different radial positions, dynamically enabling a range of drawing ratios from a single rotating component rather than requiring multiple static drawing rollers.
3Stability of the object's composition
If tapered rollers are used to eliminate yarn looseness, then yarn stability is improved, but the primary drawing function is not achieved
Solution Approach 1:
The tapered roller is designed to perform multiple functions simultaneously: it eliminates yarn looseness through its stabilizing effect on the yarn path while also providing the velocity gradient necessary for drawing. This multi-functional design integrates the yarn stabilization function with the primary drawing function within a single component.
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
Enables multi-stage drawing with a high draw ratio of 1.2 times or higher, reducing deformation and allowing for continuous drawing of synthetic fibers directly after spinning, resulting in fibers with enhanced strength and stability.
Implementation Method 1
a first step of taking up (winding) an undrawn fiber obtained by melt spinning; a second step of subsequently drawing the fiber while heating the fiber by a preliminary heating roller
Implementation Method 2
heating the fiber by a preliminary heating roller
Implementation Method 3
drawing the fiber for three times... where the drawing is performed by repeating a step of preheating the fiber by a roller heated at 80 to 110° C. and drawing the fiber
Data Source
AI summary
A drawing device for drawing a drawable material, the drawing device comprising at least a pair of tapered rollers each having a taper ratio in a range of 0.035 to 0.50, wherein the taper ratio is represented by (β−α)/2L, where β denotes a maximum diameter of the roller, α denotes a minimum diameter of the roller, and L denotes a length of a tapered portion of the roller.