WO2001020064A1

WO2001020064A1 - Spinning nozzle, spinning nipple incorporating the spinning nozzle therein, and method for manufacturing both the same

Info

Publication number: WO2001020064A1
Application number: PCT/KR2000/000920
Authority: WO
Inventors: Jeong Sik Kim
Original assignee: Jeong Sik Kim
Priority date: 1999-08-19
Filing date: 2000-08-17
Publication date: 2001-03-22
Also published as: AU6481700A

Abstract

Disclosed are a spinning nozzle having orifice with a diameter of micron unit, a spinning nipple having the spinning nozzle, and respective methods of manufacturing the spinning nozzle and the spinning nipple. The spinning nozzle has at least one coating layer surrounding the orifice. The coating layer has a metal layer and/or a non-metal layer. The method of manufacturing the spinning nozzle includes the step of forming a mandrel of a predetermined shape having a diameter of micron unit, coating a strength-reinforcing layer on a surface of the mandrel, coating a supporting layer by an electroforming process on a surface of the strength-reinforcing layer, and removing the mandrel from the strength-renforcing layer to form an orifice. The spinning nipple is obtained by fixing the spinning nozzle into a plurality of mounting holes processed by drilling and etc. For fixing the spinning nozzle in the mounting holes, thermal expansion and contraction by heating and cooling the spinning nipple are utilized. As a result, a high precision nipple having incorporated with the spinning nozzle can be manufactured in reduced manufacturing time at a decreased cost.

Description

SPINNING NOZZLE, SPINNING NIPPLE INCORPORATING THE SPINNING NOZZLE THEREIN, AND METHOD FOR MANUFACTURING BOTH THE

SAME

Background of the Invention

1. Technical Field of the Invention

The present invention relates to a spinning nozzle, a spinning nipple being incorporated with the spinning nozzle, and respective methods of manufacturing the spinning nozzle and the spinning nipple, and more particularly to a spinning nozzle having an orifice with a micron unit of its diameter size through which a spinning source material passes during manufacturing chemical or synthetic fibers.

2. Description of the Background Art Generally, spinning nipples having spinning nozzles are usually manufactured by a discharging process. In the discharging process, a tool of the same shape and size as the spinning nozzle is utilized as a negative terminal and the spinning nipple on which the spinning nozzle is formed is utilized as a positive terminal. When a voltage is supplied across the negative and positive terminals and these two terminals are approached to each other, an electric discharge occurs and nozzles having a desired shape are formed on the spinning nipple.

However, the nipples on the spinning nipple manufactured by the electric discharge are of low precision, thus numerous post-processes to the nipples are usually required. In addition, in the nipples manufactured by the electric discharge process, it is difficult to obtain an orifice having diameter as small as micron unit. Further, when one nozzle in the nipple fails or becomes worn during usage, it is necessary to replace the whole nipple rather than just one nozzle, thus increasing the cost of maintenance.

Disclosure of Invention

In view of the foregoing, it is a first object of the present invention to provide a spinning nozzle and a high precision spinning nipple, and respective methods for manufacturing the same by an electroforming process in a substantially decreased manufacturing time..

It is another object of the present invention to provide a spinning nipple, in which only a worn or failed nozzle can be replaced among a plurality of spinning nozzles incorporated therein.

According to one aspect of the present invention to accomplish the first object, there is provided a spinning nozzle including an oπfice having a diameter of micron unit; a strength-reinforcing layer surrounding the orifice; and at least one supporting layer coated by an electroforming process on the strength-reinforcing layer.

There is also provided a method for manufactuπng a spinning nozzle including the steps of: a) forming a mandrel of a predetermined shape having a diameter of micron unit; b) coating a strength-reinforcing layer on a surface of the mandrel; c) coating a supporting layer by an electroforming process on a surface of the strength-reinforcing layer; and d) removing the mandrel from the strength-reinforcing layer to form an orifice.

According to another aspect of the present invention to accomplish the first object, there is provided a spinning nipple including a spinning nozzle having an orifice with a diameter of micron unit, a strength-reinforcing layer surrounding the orifice, and at least one supporting layer coated by an electroforming process on the strength-reinforcing layer; and a plate-typed body formed with a plurality of mounting holes into each of which the spinning nozzle is fitted. There is also provided a method for manufacturing a spinning nipple including the steps of: a) forming a plurality of mounting holes in a plate-typed body; and b) fitting spinning nozzles into the mounting holes, wherein the spinning nozzles are manufactured by the steps of: a) forming a mandrel of a predetermined shape with a diameter of micron unit; b) coating a strength-reinforcing layer on a surface of the mandrel; c) coating a supporting layer by an electroforming process on a surface of the strength-reinforcing layer; and d) removing the mandrel from the strength-reinforcing layer to form an orifice. According to the present invention, a high precision spinning nipple can be manufactured by incorporating high precision spinning nozzles manufactured by an electroforminq process.

In addition, the manufacturing time of the spinning nozzle and the spinning nipple can be decreased to reduce the manufacturing cost. Further, the spinning nozzle mounted on the spinning nipple can be easily replaced, and consequently maintaining and repairing the spinning nipple can be carried out easily and efficiently.

In the electroforming process which is similar to electroplating method, a metal layer is electro-deposited by electrolysis on a mandrel having a predetermined shape, then the mandrel is removed from the metal layer having complementary shape to the metal layer. Accordingly, high precision electronic devices and mechanical components, industrial art objects having complex figures or accessories can be manufactured by the electroforming process.

Brief Description of Drawings

The above objects and other advantages of the present invention will become more apparent by describing in detail embodiments thereof with reference to the attached diawings in which: FIG. 1 shows a perspective view of a spinning nipple according to the present invention;

FIG. 2 shows a perspective view of a spinning nipple formed thereon with mounting holes for mounting of spinning nozzles, according to the present invention;

FIG. 3 shows a perspective view of the spinning nozzle according to the present invention;

FIG. 4 shows a cross-sectional view taken along a line m-HI in FIG. 3a.

FIG. 5 shows a cross-sectional view of a mandrel used for forming an orifice of the spinning nozzle according to the present invention;

FIG. 6 shows a cross-sectional view in which a strength-reinforcing layer is coated on a mandrel for an orifice;

FIG. 7 shows a cross-sectional view of a spinning nozzle prior to the removal of the mandrel; and FIG. 8 shows a cross-sectional view of a spinning nozzle after the removal of the mandrel.

Best Mode for Carrying Out the Invention

Preferred embodiments of the present invention will be described in detail below with reference to drawings.

In FIG. 1 , when a spinning machine spins out chemical or synthetic fibers, spinning raw material passes through a spinning nipple 10 by a supplied pressure. In the spinning nipple 10 a plurality of spinning nozzles 20 each of which has an orifice 23 having a micron unit in diameter. The diameter, shape and roughness of an inner surface of the orifice 23 are key factors by which a quality of the chemical or synthetic fiber is determined. Accordingly, the spinning nozzle is required to have a very high precision.

Referring to FIG. 2, the spinning nipple 10 has a plate-typed body 11 with a depth of about 300 - 500 mm. The body 11 is formed with a plurality of mounting holes 15 for mounting the spinning nozzles 20. These mounting holes 15 are formed by performing sequentially the processes of drilling, boring and reaming. It is preferred that each of the mounting holes 15 has a tapered shape in its cross-sectional view perpendicular to a longitudinal axis thereof. A mounting hole of a tapered shape is advantageous in that a resisting force of the spinning nozzle 20 caused by a pressure applied to the spinning raw material can be increased, and when replacing the worn spinning nozzle 20, the spinning nozzle 20 can be separated easily from the mounting hole 15. In FIG. 3, the spinning nozzle 20 is depicted as a hollow cylinder on which a ceramic layer and a metal layer are coated in turn on concentric circles. The spinning nozzle 20 has the orifice 23 having a micron unit in diameter, a strength-reinforcing layer 24 surrounding the orifice, and a supporting layer 25 coated with an identical depth on the strength-reinforcing layer. The strength-reinforcing layer 24 is a layer made from an abrasion resistant material having a strong property against the friction by the spinning raw material which passes through the orifice 23. Ceramic is recommended as the abrasion resistant material, and a high strength alloyed steel such as dispersion strengthened alloy may also be used as the abrasion resistant material.

The supporting layer 25, being fitted into the mounting hole 15 of the spinning nipple 10, functions to absorb contracted metamorphosis of the strength-reinforcing layer 24. Accordingly, the supporting layer 25 can be one selected from copper, chrome, nickel or cobalt. It is preferred that the supporting layer 25 is made from nickel, which has a higher ductility than the strength-reinforcing layer 24.

Alternatively, according to the application, the spinning nozzle 20 can have only one supporting layer 25 without the strength-reinforcing layer. As another alternative, this supporting layer 25 can be an alternatingly arranged layer having at least two metal layers made from different physiochemical properties or at least a set of ceramic and metal layers.

Referring to FIGs. 4 to 7 for describing a process for manufacturing the sinning nozzle 20, a mandrel 30 for forming the orifice 23 of the spinning nozzle 20 has the same size and shape as the orifice 23. It is required that the mandrel 30 should be made from a raw material which can be easily removed by chemical or physical method and which can also be utilized for forming a complex shape. An oxidative material such as copper, plastic material such as epoxy or polyester, or fusible material such as solder or wax can be recommended as the raw material of the mandrel. Particularly, if the mandrel 30 does not have an electrical conductivity, the mandrel 30 can be processed to have the electrical conductivity by a physical surface processing method such as a cathode sputtering process or by a chemical surface processing method such as a silver mirror reaction process (FIG. 4).

The conductive mandrel 30 has a deposited layer of ceramic or a dispersion strengthened alloy with a predetermined depth by a known physical vapor. Alternatively, the conductive mandrel 30 has a deposited layer of high-strength metal such as titanium or tungsten with a predetermined depth by a known chemical vapor deposition. This deposited layer functions as a strength-reinforcing layer 24 (FIG. 5).

On the mandrel 30 coated with a strength-reinforcing layer 24 thereon, a metal layer is further deposited on the strength-reinforcing layer 24 by the electroforming process. For this process, the mandrel 30, which is coated with the strength-reinforcing layer 24 thereon and functions as a cathode, and a metal plate, which is made from the same material as a layer formed on the strength-reinforcing layer of the mandrel 30 and functions as anode, are dipped into a plating bath (not shown). The plating bath can be a bath made from one principal raw material selected from the group consisting of Ni(NH₄S0₃)₂ ^• 2H₂0 and H₃B0₃; NiCI₂ • 6H₂0 and H₃B0₃; Ni(BF₄)₂ and H₃B0₃; NiCI₂ ^■ 6H₂0,d H₃B0₃ and NiS0₄ ^• 6H₂0; and NiS0₄ ^■ 6H₂0. Preferably, the Ni(NH₄S0₃)₂ ^• 2H₂0 is recommended as the best among the above principal raw materials. Here, working conditions of the plating bath with the principal raw material are as follows: 550-650 g/l,

preferably 450-650 g/l in quantity; 2.0-5.0, preferably 3.5-5.0 in pH; 35-75 °C, preferably 40-60 °C in temperature; and 2.5~30A/dm², preferably 15~30A/dm² in current density. Under these conditions, the mandrel having coated with the strength-reinforcing layer 24 is dipped into the plating bath for 100-500 hours.

Accordingly, during the electroforming process, the strength-reinforcing layer 24 of the mandrel 30 is formed with a plating layer thereon by the electrolysis of metal. The deposited plating layer functions as the supporting layer 25. Here, the current density and dipping time determines the depth of the plating layer dependent on an outer diameter of the spinning nozzle.

The mandrel 30 formed with the supporting layer 25 on the strength-reinforcing layer 24 by the electroforming process is separated from the strength-reinforcing layer by a physical or chemical method. For example, if the mandrel 30 is made from copper (Cu), the mandrel 30 is dipped into an acid solution. Then, the copper is separated from the strength-reinforcing layer 24 by oxidation. If the mandrel 30 is made from lead (Pb), the mandrel 30 is dipped into a container in which the inner temperature is maintained over a melting temperature of lead, Then, the lead is separated from the strength-reinforcing layer 24 by melting. Accordingly, the strength-reinforcing layer 24 and the supporting layer 25 removed with the mandrel 30 function as the spinning nozzle 20, and a space obtained by the removal of the mandrel 30 becomes the orifice 23. In consideration of processing margin, it is preferable that the outer diameter of the spinning nozzle 20 is larger than the inner diameter of the mounting hole 15 of the spinning nipple 10.

Though the spinning nozzle 20 is manufactured to have a tapered shape which is complementary to the mounting hole 15 of the spinning nipple 10, the spinning nozzle 20 is a little larger than the mounting hole 15 of the spinning nipple 10. The difference in size between the outer diameter of the spinning nozzle 20 and the inner diameter of the mounting hole 15 of the spinning nipple 10 is provided to tightly fix the spinning nozzle 20 into the mounting hole 15 of the spinning nipple by thermal expansion and contraction, in which the spinning nipple 10 is heated and then cooled. For this process, the spinning nipple 10 is contained into a container which radiates a heat of high temperature and as a result, the inner diameter of the mounting hole 15 increases slightly by thermal expansion. Then, the spinning nozzle 20 is inserted into the mounting hole 15 with the increased inner diameter. Thereafter, by cooling the spinning nipple 10, the spinning nozzle 20 can be fitted tightly in the mounting hole 15.

Then, the spinning nipple 10 which is tightly fixed with the spinning nozzle 20 is subjected to the electroforming process to finally obtain a desired spinning nipple 10.

Herein below, a method for manufacturing a spinning nipple 10 having directly formed with a spinning nozzle 20 by electroplating method, according to another embodiment of the present invention, will be described

The spinning nipple 10 is formed with a plurality of mounting holes 15 with a diameter of about 10-20 mm by drilling, boring and reaming (refer to FIG. 2). The spinning nipple 10 having the mounting holes 15 is processed under the same working conditions described for the electroforming process.

Accordingly, an electroplating layer is formed on the inner surface of the mounting holes 15 of the spinning nipple 10 by electrolysis. The formation of the electroplating layer is continued until an orifice having a micron unit in diameter is obtained, through which the spinning raw material for the chemical or synthetic fiber can pass. The manufacturing of the spinning nipple 10 is finished by forming the electroplating layer which covers the orifice having the micron unit in diameter.

Industrial Applicability

Although the above description on the electroplating bath for electroforming process is preferred by the nickel electroplating bath, it should be noted that a steel electroplating bath, a chrome electroplating bath, and a copper electroplating bath can also be used. And, the working conditions of the electroplating bath can be varied to carry out the invention by a person of ordinary skill in the art, without departing the scope of the invention as described above.

While the present invention has been particularly shown and described with reference to particular embodiments thereof, it is understood that the present invention should not be limited to this preferred embodiment, but various changes and modifications can be made by one skilled in the art within the spirit and scope of the invention as hereinafter claimed.

Claims

1. A spinning nozzle comprising: an orifice with a diameter of micron unit; a strength-reinforcing layer surrounding the orifice; and at least one supporting layer coated by an electroforming process on the strength-reinforcing layer.

2. The spinning nozzle as claimed in claim 1 , wherein the strength-reinforcing layer is made from one selected from the group consisting of ceramic, dispersion strengthened ally, titanium, tungsten, cobalt, and chrome.

3. The spinning nozzle as claimed in claim 1 , wherein the supporting layer is made from metal.

4. The spinning nozzle as claimed in claim 3, wherein the metal is one selected from the group consisting of nickel, iron, chrome, copper, and cobalt.

5. A spinning nipple comprising: a spinning nozzle; and a plate-typed body formed with a plurality of mounting holes into each of which the spinning nozzle is fitted, wherein the spinning nozzle has an orifice with a diameter of micron unit; a strength-reinforcing layer surrounding the orifice; and at least one supporting layer coated by an electroforming process on the strength-reinforcing layer.

6. The spinning nipple as claimed in claim 5, wherein the supporting nozzle of the spinning nozzle and the mounting hole of the plate-typed body are tapered to have a complementary shape.

7. A method of manufacturing a spinning nozzle, comprising the steps of: a) forming a mandrel of a predetermined shape having a diameter of micron unit; b) coating a strength-reinforcing layer on a surface of the mandrel; c) coating a supporting layer by an electroforming process on a surface of the strength-reinforcing layer; and d) removing the mandrel from the strength-reinforcing layer to form an orifice.

8. The method as claimed in claim 7, wherein the mandrel is a plastic material or a fusible material.

9. The method as claimed in claim 8, wherein the plastic material or fusible material is one selected from the group consisting of epoxy, polyester, wax, solder, and copper.

10. The method as claimed in claim 7, wherein the strength-reinforcing layer is made from one selected from the group consisting of ceramic, dispersion strengthened ally, titanium, tungsten, cobalt, and chrome.

11. The method as claimed in claim 7, wherein the supporting layer is made from metal.

12. The method as claimed in claim 11 , wherein the metal is one selected from the group consisting of nickel, iron, chrome, copper, and cobalt.

13. The method as claimed in claim 7, wherein the mandrel of step d) is melted in a container of a high temperature to be removed from the strength-reinforcing layer.

14. The method as claimed in claim 7, wherein the mandrel of step d) is oxidized in a container containing an oxidative solution to be removed from the strength-reinforcing layer.

15. A method of manufacturing a spinning nipple, comprising the steps of: a) forming a plurality of mounting holes in a plate-typed body; and b) fitting a spinning nozzle into the mounting hole, wherein the spinning nozzle is manufactured by the steps of: a) forming a mandrel of a predetermined shape having a diameter of micron unit; b) coating a strength-reinforcing layer on a surface of the mandrel; c) coating a supporting layer by an electroforming process on a surface of the strength-reinforcing layer; and d) removing the mandrel from the strength-reinforcing layer to form an orifice.

16. The method as claimed in claim 15, further comprising the step of coating a metal layer by the electroforming process on the plate-typed body formed with the spinning nozzle therein, after step b),

17. The method as claimed in claim 15, wherein the plate-typed body is fitted into the spinning nozzle by thermal expansion.

18. The method as claimed in claim 17, wherein the supporting layer of the spinning nozzle and the mounting hole of the plate-typed body are respectively tapered to have a complementary shape.

19. A method of manufacturing a spinning nipple, comprising the steps of: a) forming a plurality of mounting holes in a plate-typed body; b) dipping the plate-typed body into an electroplating bath while supplying a voltage; and c) coating at least one metal layer on an inner surface of the mounting holes of the plate-typed holes.