Ultrafine Fiber Production Device with Segmented Heating
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Solution Overview
Problem
Existing ultrafine fiber production methods face challenges in achieving stable and uniform fiber diameters due to turbulent flows and gasification issues, leading to increased fiber diameter variation and defects.
Innovation Solution
The ultrafine fiber production device employs a first heating unit, nozzle unit, hot air heating unit, hot air blowing unit, and second heating unit, where the thermoplastic resin is melted, extended by hot air, and further heated through a through-hole in the second heating unit to prevent vibration and gasification, ensuring stable fiber formation and uniform diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a second heating device is disposed immediately below a spinning nozzle to obtain ultrafine fibers, then fiber fining is enhanced, but fiber gasification occurs and fiber formation becomes unstable
Solution Approach 1:
The heating process is divided into two distinct stages: a first heating device for initial resin heating and fiber formation, and a second heating device for subsequent fiber fining. This segmentation allows each heating stage to be optimized independently, preventing gasification while achieving uniform fiber diameter.
Solution Approach 2:
The first heating device performs preliminary heating and fiber formation before the resin reaches the second heating device. This preliminary action ensures the resin is properly prepared and stabilized, preventing gasification when exposed to the second heating device.
2Length of moving object
If hot air is blown to extend melted resin for fiber forming, then fiber extension is achieved, but turbulent flow causes fiber vibration and diameter variation
Solution Approach 1:
The hot air blowing is applied locally and controllably to specific regions of the melted resin, ensuring uniform extension without creating turbulent flows that would cause fiber vibration and diameter variation.
3Manufacturing precision
If multiple heating devices and hot air blowing units are added to improve fiber formation, then fiber fining is enhanced, but device complexity increases
Solution Approach 1:
The first and second heating devices are integrated into a coordinated system where their functions are merged in sequence, allowing efficient fiber formation and fining without requiring excessive independent components.
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 method enables the production of a large amount of ultrafine fibers with a thin and uniform fiber diameter without breaks, improving stability and reducing fiber defects, as demonstrated by the comparison with comparative examples.
Implementation Method 1
a first heating unit for melting a thermoplastic resin
Implementation Method 2
a hot air heating unit for producing high-temperature gas; a hot air blowing unit for performing fiber forming by blowing the high-temperature gas produced by the hot air heating unit to the melted thermoplastic resin discharged by the nozzle unit and by extending the thermoplastic resin
Implementation Method 3
a second heating unit having a through-hole which allows the thermoplastic resin subjected to fiber forming by the hot air blowing unit to pass through for heating
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
An ultrafine fiber production device has a first heating unit, a nozzle unit, a hot air heating unit, a hot air blowing unit, a second heating unit, and a fiber collecting unit. The first heating unit melts a thermoplastic resin. The nozzle unit discharges the thermoplastic resin melted by the first heating unit. The hot air blowing unit performs fiber forming by blowing high-temperature gas produced by the hot air heating unit to the melted thermoplastic resin discharged by the nozzle unit and by extending the thermoplastic resin. The second heating unit further heats, extends, and fines produced fibers. The fiber collecting unit collects the thermoplastic resin in a fibrous form which is fined by the second heating unit.