JP2015514163A - Spinneret that improves spinning productivity - Google Patents

Abstract

According to the present disclosure, a spinneret is used in that embodiment to extrude a molten plastic polymer and use it to form fibers. The spinneret includes a plurality of openings provided along a plurality of contours. This improves spinning productivity by increasing the density of the openings, and at the same time eliminates the risk of fiber fusion by properly maintaining the distance between the openings.

Description

FIELD OF DISCLOSURE The present disclosure relates to a melt spinning process. In particular, it relates to a spinneret used for melt spinning.

Definitions As used herein, the expressions "microdenier fiber" and "microfiber" refer to synthetic fibers that are thinner than 1 to 1.3 denier or decitex per strand.

  As used herein, the expression “supermicrodenier monofilament” refers to a synthetic fiber having a dimension of .37 dpf (denier per monofilament).

  Polymer fibers are generally produced by a melt spinning process. In the melt spinning process, the polymer is melted and pumped to a spinneret or a die having a plurality of openings. The melted polymer passes through a plurality of openings formed in the die or die to form a molten polymer fiber. The molten polymer fiber extruded from the opening is cooled or rapidly cooled, solidified, and wound around a bobbin through a take-out wheel. By stretching the fiber both in the melted state and after solidification, the polymer chain direction can be aligned with the fiber axis. Polymers such as polyethylene terephthalate and nylon 6,6 are used in large quantities for melt spinning.

  The molten polymer is extruded from a plurality of openings arranged in a die or die so that molten fibers can be easily formed. The more the number of openings arranged in the base, the more fibers are formed, that is, the productivity of the base is improved. Spinning productivity is proportional to the density of openings in the die. More particularly, spinning productivity is proportional to the number of openings in the unit of the die area. In particular, increasing the number of openings in the die increases the spinning productivity. However, there are structural limitations in conventional bases, so that the density of openings cannot be increased beyond a certain limit. Increasing the number of openings increases the risk of single fiber fusing during spinning and adversely affects product quality and process productivity. Thus, the conventional spinneret cannot be expected to increase the density of the openings beyond the limit, and according to the conventional spinneret, the production amount of microfiber or super microdenier fiber cannot be increased beyond a certain limit. Thus, according to the conventional spinneret, the productivity of spinning is limited.

  There are several prior art disclosure documents relating to die for melt spinning of plastic polymers.

For example, an acquired US Pat. No. 6,926,854 (hereinafter referred to as a '854 acquired US Patent) discloses a method for producing a polyester fineness multifilament. According to it, the length of the quench retarding wind guide plate in the melt spinning process for the production of polyester hollow fiber using rapid cooling by radial blow from the inside to the outside is (2.8060 inch x passage amount ÷ number of fibers ² ). The length of the quenching air pipe is 15 to 40 cm, and the blowing speed of the quenching air is 0.2 to 0.6 m / s. As the layout of the spinneret openings, the difference between the diameter of the circle consisting of the outermost opening and the diameter of the circle consisting of the innermost opening is set to 20 mm or less. Also, the difference between the diameter of the circle consisting of the innermost opening and the diameter of the quick air-cooled air duct is at least 12 mm and less than 33 mm. The density of openings in the spinneret layout ranges from 7 to 15 per square centimeter, but this is a very small number. The use of a spinneret according to the disclosure of the '854 acquired U.S. patent has to say that the productivity of spinning is low, and for the production of polyester fineness multifilaments, Complex and ineffective.

  Similarly, published Japanese patent application JP4300319 (hereinafter referred to as' 319 published Japanese patent application) discloses a method for producing polyester fiber and a spinneret used therefor. According to this, the polyester fiber is melt-spun at a high speed of 5000 m / min or more. The opening of the base is provided in a plurality of concentric circles, and the diameter of the opening on the inner periphery for spinning is larger than the opening on the outer periphery. It is assumed that cooling fibers are blown uniformly over the entire outer periphery of the fibers just melt-spun to quench them. As a result, a multifilament yarn of polyester fibers composed of many single fibers is melt-spun. However, the base and manufacturing method according to the '319 published Japanese patent application are complex and ineffective.

  Published Chinese patent application CN 1752301 (hereinafter referred to as' 301 published Chinese patent application) discloses a method of producing fine denier acrylic fibers by dry spinning and melt die. In this method, technical conditions of the original patent Dupont acrylic fiber dry spinning are adjusted as follows. That is, the temperature difference between the inside and outside of the material is widened, the temperature and flow rate of nitrogen gas, the washing temperature, the number and speed of drafts are controlled, and the cotton oil-based fiber oil agent is used. The '301 published Chinese patent application also discloses a design of a spinneret that is densely perforated. The aperture is 0.09 to 0.13 mm and the aperture is placed on 15 to 21 concentric circles. Thereby, it is said that mass production of fine denier acrylic fiber is possible. However, the method of dry spinning fine denier acrylic fiber according to the '301 published Chinese patent application and the spinneret therefor are complicated and ineffective.

  From the above, it is felt that it is necessary to increase the density of the openings of the spinneret and increase the production amount of spinning. Furthermore, it is felt that there is a need to increase the production amount of spinning while maintaining the quality of the product and stabilizing the productivity of the process in production to a certain level. In addition, it is felt that there is a need to increase the density of the spinneret openings and increase the amount of spinning produced while eliminating the risk of fiber fusion during spinning.

Some of the problems of the present disclosure that are solved in at least one embodiment are as follows:

  One object of the present disclosure is to improve one or more of the problems of the prior art or provide a useful alternative.

  One object of the present disclosure is to provide a spinneret that improves spinning productivity.

  Another problem of the present disclosure is to provide a spinneret with a high opening density.

  Yet another object of the present disclosure is to provide a spinneret with openings strategically arranged to increase the number of openings.

  In addition, another object of the present disclosure is to provide a spinneret that improves process output in fiber production.

  In addition, another object of the present disclosure is to provide a spinneret that eliminates the risk of fiber fusion in spinning with a die having a high aperture density.

  A further problem of the present disclosure is to provide a spinneret for use in a melt spinning process for the production of microfibers and super microdenier fibers.

  Other problems and advantages of the present invention will be clarified by the following description together with the attached charts, but these charts and explanations do not limit the scope of the present invention.

SUMMARY OF THE INVENTION An extruded spinneret of molten plastic polymer for fiber formation in accordance with certain embodiments of the present disclosure is provided. The spinneret has multiple openings arranged along multiple contours to improve the spinning productivity by increasing the density of the openings, while ensuring the distance between the openings and avoiding the risk of fiber fusion. Openings are included.

  As a standard, the aperture density is 20 to 45 per square centimeter of spinneret surface area. The distance between the openings is 1 to 5 mm.

  According to one embodiment, the spinneret has an aperture density in the range of 20-60 per square centimeter of its surface area, and the distance between the apertures is 1 to 5 mm.

  According to another embodiment, the spinneret has an aperture density in the range of 20-45 per square centimeter of its surface area, and the distance between the apertures is 1.5 to 2.2 mm.

  Generally, the outline is a plurality of concentric circles.

  According to one embodiment, the openings are located along 16 concentric circles.

  Generally, the molten polymer is a molten polyester.

  As standard, the spinneret is a base with a diameter of 229 mm and an opening of 3900.

  According to another embodiment, the spinneret is a base having a diameter of 229 mm and an opening of 4208.

  Preferably, the spinneret is used in a polyester staple fiber (PSF) spinning machine.

  Generally, a spinneret includes a plurality of mounting openings opened along the outer periphery to facilitate its mounting.

  Preferably, at least two of the mounting openings arranged so as to be diametrically opposite to each other are countersunk holes.

  As standard, the spinneret includes perforations placed on its periphery.

Outline Description of Attached Diagrams The contents of the present disclosure will be further clarified in the following description together with the attached diagrams, but do not limit the scope of the present disclosure. Below is a summary of the attached chart:

FIG. 1a is a front view of a spinneret having a diameter of 229 mm and an opening of 3900 in an embodiment consistent with the present disclosure. FIG. 1b is a cross-sectional view of the spinneret of FIG. 1a on the XX line. FIG. 2a is a front view of a spinneret with a diameter of 229 mm and an opening of 4208 in a further improved embodiment in accordance with the present disclosure. further FIG. 2b is a cross-sectional view of the spinneret of FIG. 2a on the X-X 'line.

Detailed Description of Attached Charts The present invention will be clarified by the following description together with the attached charts, but these charts and descriptions do not limit the scope of the present invention. It is shown only as an example and illustration method.

  Details of the embodiments of the present disclosure and their functions and advantages are described in the following examples, which do not limit the patent. Descriptions of known techniques, components, and processing methods are omitted so as not to unnecessarily impair the clear description of the embodiments. The embodiments described below are merely for ease of understanding, and are intended to enable specialists to realize the contents of the present disclosure. Thus, the examples should not be construed as limiting the scope of the embodiments.

  The present disclosure is aimed at providing an improved spinneret for forming fibers by extrusion of plastic polymers. The improved spinneret has predetermined openings. More specifically, the arrangement is such that more openings can be made in a limited area, thereby improving the spinning productivity and at the same time maintaining the proper distance between the openings to fuse the fibers. It is something to exclude.

  FIG. 1a is a front view of a spinneret with an opening of 3900 versus a diameter of 229 mm and a conventional approximately 3300 circular opening in an embodiment consistent with the present disclosure.

  FIG. 1b is a cross-sectional view of the spinneret of FIG. 1a on the XX line. FIG. 1a shows a spinneret with a plurality of openings indicated by reference number (1), the openings being arranged appropriately according to their quantity along 16 concentric circles. . For example, there are 202 openings along the innermost circle, and 208 openings along the next circle. The same applies thereafter. Such an arrangement makes it easier to place more openings on a specific area, ie the area of a base with a diameter of 229 mm. Furthermore, the arrangement of such openings in the spinneret is suitable for the formation of micro and super micro deniers. In addition, the spinneret includes markings indicating the number of openings thus arranged to prevent confusion. For example, the spinneret shown in FIG. 1a includes a 3900 marking, which indicates that there are 3900 openings located in the base. This marking may be by etching or any other process.

  Furthermore, there are 16 fixing and mounting openings 2 along the outer periphery of the spinneret. These 16 openings are also arranged concentrically with respect to the 16 concentric openings. In addition, two of the 16 fixing openings 2 arranged so as to be diametrically opposite to each other are countersunk holes. Further, a pair of openings 3 and one opening 4 and 5 are arranged on the periphery of the base.

  FIG. 2a is a front view of a spinneret with a diameter of 229 mm and 4208 circular openings versus a conventional approximately 3300 circular opening in an embodiment consistent with the present disclosure. FIG. 2a shows a spinneret with a plurality of openings indicated by reference number (11), the openings being arranged appropriately according to their quantity along a circle of 16 concentric circles. . Furthermore, there are 16 fixing and mounting openings 12 along the outer periphery of the spinneret. These openings are also arranged concentrically with respect to the 16 concentric openings. Two of the 16 fixing openings 2 arranged so as to be diametrically opposite to each other are countersunk holes. Further, a pair of openings 13 and one opening 14 and 15 are arranged on the periphery of the base.

  FIG. 2b is a cross-sectional view of the spinneret of FIG. 2a on the X-X 'line. FIG. 2a shows a spinneret with a plurality of openings indicated by reference number (11), the openings being arranged appropriately according to their quantity along a circle of 16 concentric circles. . For example, there are 218 openings along the innermost circle and 224 openings along the next circle. The same applies thereafter. Such an arrangement makes it easier to place more openings on a specific area, ie the area of a base with a diameter of 229 mm. Furthermore, the arrangement of such openings in the spinneret is suitable for the formation of micro and super micro denier. In addition, the spinneret shown in FIG. 2a includes the marking 4208, which indicates that there are 4208 openings located in the base. This marking may be by etching or any other process.

  The other functions and parts of the spinneret according to the present disclosure shown in FIGS. 2a and 2b are exactly the same as the functions and parts shown in FIGS. 1a and 1b.

  The present disclosure provides a spinneret with a plurality of openings arranged strategically, thereby increasing the density of openings, improving the productivity of spinning, while maintaining product quality and producing processes through manufacturing. Stabilize the amount. The openings strategically placed in the spinneret eliminate the risk of fiber fusion by maintaining an appropriate distance between the openings.

  The spinneret according to the present disclosure is particularly suitable for use in polyester short fiber (PSF) spinning machines, but may be used in any other type of spinning machine.

  The spinneret according to the present disclosure has the same area as a conventional base. However, as shown in FIGS. 1a, 1b, 2a, and 2b and described above, the openings are strategically arranged, and the density of the openings in the base is increased. Furthermore, the distance between the openings is adjusted to prevent fiber fusion during spinning. In addition, the spinneret opening arrangement according to the present disclosure is suitable for micro and super micro denier.

  A test was conducted to verify the efficiency of the spinneret according to the present disclosure. A spinneret according to the present disclosure was tested in a commercial spinning machine. High production and normal performance were observed. The resulting tow was inspected for defects but was comparable to existing denier products. The use of a spinneret according to the present disclosure has increased productivity by at least 10 percent in spinning. The resulting tow was observed to have normal production performance when processed by a commercial draw machine. The fiber finally obtained was free of defects.

  However, the preferred embodiments described above do not limit the scope of the present disclosure. The foregoing detailed description is provided for purposes of illustration and description only.

  Details of the embodiments of the present disclosure and their functions and advantages are described with examples, which do not limit the patent. Descriptions of known techniques, components, and processing methods are omitted so as not to unnecessarily impair the clear description of the embodiments. The embodiment used here is merely for ease of understanding and is intended to enable a specialist to implement the contents of the present disclosure. Thus, the examples should not be construed as limiting the scope of the embodiments.

  The above specific examples can be easily modified and applied based on current knowledge, so that they can be widely applied immediately without starting from basic concepts, and deepen understanding by analogy. It is a general indication of the nature of the invention so that it can. It should be understood that the expressions and terms used herein are for illustrative purposes and are not intended to be limiting. In addition, although the examples are preferred, skilled persons will recognize that they can be modified and applied while inheriting the intent and scope of the examples. .

Technical features and economic implications of this disclosure The method according to the present disclosure has several technical features, including but not limited to:
-Spinneret that improves spinning productivity;
A spinneret with openings arranged strategically so that the number of openings can be increased;
-Spinneret with increased opening density;
-Spinnerets that improve production and maintain stable production in fiber manufacturing;
• Spinnerets that eliminate the risk of fiber fusion in spinning; in addition • Spinnerets used in the melt spinning process in the production of micro and super micro denier fibers.

  As used throughout this specification, the word “comprise” / “comprises” / “comprising”, or variations thereof, imply inclusion of the stated elements, integers or steps, but other elements. It is understood that no integer or step exclusion is implied.

  The use of the expression "at least" / "at least one" ("at least" / "at least one") embodies published patents to achieve or achieve one or more desired purposes or results. It may be put in, suggesting the use of one or more elements or components or quantities.

  All discussions regarding documents, materials, devices, papers, etc. contained herein are made solely for the purpose of arranging the present invention. This should be considered to admit that part or all of the present invention constitutes part of the existing technology, or that it has existed as general knowledge before the date of the present invention. It is not a thing.

  The various physical parameter, dimension and quantity values shown here are only approximate values, and in the present invention and in the claims, values higher than the physical parameter, volume and quantity values shown therein are Unless otherwise stated, it is expected to be acceptable.

  Specific examples can be easily modified and applied based on current knowledge, so that they can be applied immediately without starting from basic concepts, and deepen understanding by analogy. It is a general indication of the nature of the invention so that it can. It should be understood that the expressions and terms used herein are for illustrative purposes and are not intended to be limiting. In addition, although the examples are preferred, skilled persons will recognize that they can be modified and applied while inheriting the intent and scope of the examples. . The example shown here is for the purpose of facilitating the understanding of the embodiment and for the purpose of facilitating the realization thereof, and not for limiting the scope of the embodiment. .

Claims (14)

  An extruded spinneret of molten plastic polymer for fiber formation to improve the spinning productivity by increasing the density of the openings while ensuring the distance between the openings to avoid the risk of fiber fusion. , Including a plurality of openings arranged along a plurality of contours.   The spinneret according to claim 1, wherein the opening density is 20 to 45 per square centimeter of surface area of the spinneret and the distance between the openings is 1 to 5 mm.   The spinneret of claim 1, wherein the opening density is 20 to 60 per square centimeter of surface area of the spinneret and the distance between the openings is 1 to 5 mm.   The spinneret according to claim 1, wherein the opening density is 20 to 45 per square centimeter of surface area of the spinneret and the distance between the openings is 1.5 to 2.2 mm.   The spinneret according to claim 1, wherein the contour is a circle having a plurality of concentric circles.   The spinneret of claim 1 wherein the openings are located along 16 concentric circles.   The spinneret of claim 1 wherein the polymer is polyester.   The spinneret of claim 1, wherein the base comprises and includes a 229 mm diameter and 3900 aperture.   The spinneret of claim 1, wherein the base includes and includes a 229 mm diameter and 4208 aperture.   The spinneret of claim 1 wherein the openings are arranged to facilitate the formation of micro and super micro denier fibers.   The spinneret of claim 1 adapted for use in a polyester short fiber (PSF) spinning machine.   The spinneret of claim 1 including a plurality of mounting openings opened along its outer periphery to facilitate its mounting.   11. The spinneret according to claim 10, wherein at least two of the mounting openings arranged so as to be directly opposite in diameter are countersunk holes.   The spinneret according to claim 1, comprising perforations disposed on the periphery thereof.

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