高效短流程多头纺PET POY成型工艺技术研究
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摘要
本文以德国巴马格公司WINGS POY纺丝设备为平台,以经典的熔融纺丝成形理论为指导,通过解析该纺丝设备基本原理和工艺流程,建立WINGS POY同轴卷绕不同丝饼纺丝成形模型,分析同一纺丝位(同一卷绕轴)上不同丝饼间成形纤维的超分子结构及其热力学性能间的差异,并与传统ACW POY纺丝工艺进行对比分析,分析产生差异的主要因素,并得到一些有效的结果,可为减小丝饼间的结构与性能的差异,提高产品品质、改进设备和优化工艺提供理论指导。
本文选取PET POY (277dtex/288f)长丝为研究对象,以所建立的模型为基础,结合纺丝成形理论对同一卷绕轴不同丝饼纤维的结晶取向结构及热力学性能进行测试分析。通过声速法测试试样的取向度；利用差热分析仪测试了试样的结晶度；利用条干均匀度分析仪测试试样条干不匀率；利用电子单纱强力仪测试了试样的断裂强度、断裂伸长率、初始模量、60%伸度时强力波动值等力学性能指标；以及测试试样沸水收缩率等指标,综合分析同一纺丝位不同丝饼试样的结构性能的差异,发现：
(1)同一纺丝位不同丝束由于在纺丝过程中各自的纺丝路径不同,外部丝饼丝束的纺程长度大于中间丝束,且外部丝束与导丝钩的包覆角大于中间丝束,导致丝束在纺丝线上所受到的张力以及波动情况不同,使得最终形成的纤维在结构性能及结构性能的稳定性上存在差异。
(2)同轴卷绕中间丝饼的取向度低于外部丝饼,结晶度也是中间丝饼低于外部丝饼,但是中间丝饼结晶的结构的均匀性规整性优于外部丝饼。
(3)在丝束宏观形态方面,同一纺丝位外部丝饼试样的条干不匀率高于中间丝饼。同轴卷绕的不同丝饼,中间丝饼虽然取向度与结晶度略低于外部丝饼,但中间丝饼的微观结构的规整性好于外部丝饼,使得中间丝饼的拉伸断裂强度、断裂伸长率以及沸水收缩率均大于外部丝饼,且各值的波动性也是中间丝饼低于外部丝饼,表征POY结构均匀性的60%伸度强力波动值也是中间丝饼低于外部丝饼。
(4) WINGS系统由于将传统POY纺丝系统中的导丝辊、网络空气喷嘴等部件都集合到卷绕头上,使得纺程大大缩短,减少了车间内空气流动对纺丝线上丝束的扰动；又在丝路上丝束与导丝辊的包覆角减小,减少了丝束与导丝辊的接触面积,降低了纺丝线上导丝辊等部件由于机械振动对丝束的影响,使得所生产同轴卷绕不同丝饼的POY长丝具有更均一的微观结构,中间丝饼与外部丝饼结构与性能各项指标的差异小于传统POY工艺,力学性能指标均优于传统工艺,且各项指标的波动值(CV值)小于传统工艺,使得WINGSPOY工艺产品品质总体优于传统工艺。
This paper is based on the WINGS POY spinning process of Barmag company in Germany, and the classic melt spinning theory is taken as a guide, also through studying and analysis the formation mechanism and difference of structure and properties about different wire cake at same spinning position. Finding out the main factors that cause differences, by improving the equipment and optimizing the process to reduce the difference of the structure and properties between wire cake at same spinning position, so as to improve the quality of product.
About the spinning experiment, we obtain 277dtex/288f PET POY under the traditional ACW POY spinning process and the WINGS POY spinning process. The crystallinity, the sonic velocity of orientation factor, velocity modulus, boiling water shrinkage are tested and analyzed by DSC, the digital fiber sound velocimeter and so on. Through the research and analysis, we can find that:
(1) At the same spinning position, the length of spinning path of two sides tows is longer than the tows middle of spinning position, the angle of external tow coated with wire guide hook is greater than the tow middle of spinning position, leading to the spinning tension and fluctuation of the tow at side of spinning position is larger than the tow middle of spinning position. There are differences of structure and properties between different rolls at same spinning position.
(2) The orientation degree and the crystallinity of intermediate filament winding cake are lower than the external yam cake, but the crystal structure of intermediate filament winding cake is more even.
(3) At the same spinning-bit, the yarn irregularity of external wire cake is higher than the middle filament roll. About different filament rolls winded by same winder and meantime, as the orientation degree and crystallinity of external filament winding cake is higher, but crystal structure of intermediate filament winding cake is more even. The breaking strength, elongation at break and boiling water shrinkage rate of intermediate filament cake are higher than the external wire cake, and the CV values of all three indicators of intermediate filament cake are lower than the external wire cake. The fluctuations of strength when being extended to 60% of elongation at break is a characterization that shows structural uniform of POY. The intermediate filament cake has lower fluctuation compared with the external wire cake cakes. That means the structure of the intermediate filament uniformity is better than the external wire cake.
(4)Compared with the traditional ACW POY spinning process, the WINGS POY spinning system gathers the guide wire roller, network air nozzles and other components to the winding head, makes the spinning length significantly reduced, also reduce the disturbance caused by air flow inside the shop. The angle of tow coated with wire guide hook is reduced. That reduces the contact area of tow with the guide wire roller, and the impact of mechanical vibration. Making the filament rolls at the same spinning position has more even structure. The difference is less than the traditional ACW POY spinning process between different filament roll spun at coaxial winding. The mechanical properties are superior to the traditional process. Coefficient of variation of the experimental values of WINGS POY system are lower than the traditional ACW POY system. The quality of WINGS POY process product is superior to the traditional process.
本文选取PET POY (277dtex/288f)长丝为研究对象,以所建立的模型为基础,结合纺丝成形理论对同一卷绕轴不同丝饼纤维的结晶取向结构及热力学性能进行测试分析。通过声速法测试试样的取向度；利用差热分析仪测试了试样的结晶度；利用条干均匀度分析仪测试试样条干不匀率；利用电子单纱强力仪测试了试样的断裂强度、断裂伸长率、初始模量、60%伸度时强力波动值等力学性能指标；以及测试试样沸水收缩率等指标,综合分析同一纺丝位不同丝饼试样的结构性能的差异,发现：
(1)同一纺丝位不同丝束由于在纺丝过程中各自的纺丝路径不同,外部丝饼丝束的纺程长度大于中间丝束,且外部丝束与导丝钩的包覆角大于中间丝束,导致丝束在纺丝线上所受到的张力以及波动情况不同,使得最终形成的纤维在结构性能及结构性能的稳定性上存在差异。
(2)同轴卷绕中间丝饼的取向度低于外部丝饼,结晶度也是中间丝饼低于外部丝饼,但是中间丝饼结晶的结构的均匀性规整性优于外部丝饼。
(3)在丝束宏观形态方面,同一纺丝位外部丝饼试样的条干不匀率高于中间丝饼。同轴卷绕的不同丝饼,中间丝饼虽然取向度与结晶度略低于外部丝饼,但中间丝饼的微观结构的规整性好于外部丝饼,使得中间丝饼的拉伸断裂强度、断裂伸长率以及沸水收缩率均大于外部丝饼,且各值的波动性也是中间丝饼低于外部丝饼,表征POY结构均匀性的60%伸度强力波动值也是中间丝饼低于外部丝饼。
(4) WINGS系统由于将传统POY纺丝系统中的导丝辊、网络空气喷嘴等部件都集合到卷绕头上,使得纺程大大缩短,减少了车间内空气流动对纺丝线上丝束的扰动；又在丝路上丝束与导丝辊的包覆角减小,减少了丝束与导丝辊的接触面积,降低了纺丝线上导丝辊等部件由于机械振动对丝束的影响,使得所生产同轴卷绕不同丝饼的POY长丝具有更均一的微观结构,中间丝饼与外部丝饼结构与性能各项指标的差异小于传统POY工艺,力学性能指标均优于传统工艺,且各项指标的波动值(CV值)小于传统工艺,使得WINGSPOY工艺产品品质总体优于传统工艺。
This paper is based on the WINGS POY spinning process of Barmag company in Germany, and the classic melt spinning theory is taken as a guide, also through studying and analysis the formation mechanism and difference of structure and properties about different wire cake at same spinning position. Finding out the main factors that cause differences, by improving the equipment and optimizing the process to reduce the difference of the structure and properties between wire cake at same spinning position, so as to improve the quality of product.
About the spinning experiment, we obtain 277dtex/288f PET POY under the traditional ACW POY spinning process and the WINGS POY spinning process. The crystallinity, the sonic velocity of orientation factor, velocity modulus, boiling water shrinkage are tested and analyzed by DSC, the digital fiber sound velocimeter and so on. Through the research and analysis, we can find that:
(1) At the same spinning position, the length of spinning path of two sides tows is longer than the tows middle of spinning position, the angle of external tow coated with wire guide hook is greater than the tow middle of spinning position, leading to the spinning tension and fluctuation of the tow at side of spinning position is larger than the tow middle of spinning position. There are differences of structure and properties between different rolls at same spinning position.
(2) The orientation degree and the crystallinity of intermediate filament winding cake are lower than the external yam cake, but the crystal structure of intermediate filament winding cake is more even.
(3) At the same spinning-bit, the yarn irregularity of external wire cake is higher than the middle filament roll. About different filament rolls winded by same winder and meantime, as the orientation degree and crystallinity of external filament winding cake is higher, but crystal structure of intermediate filament winding cake is more even. The breaking strength, elongation at break and boiling water shrinkage rate of intermediate filament cake are higher than the external wire cake, and the CV values of all three indicators of intermediate filament cake are lower than the external wire cake. The fluctuations of strength when being extended to 60% of elongation at break is a characterization that shows structural uniform of POY. The intermediate filament cake has lower fluctuation compared with the external wire cake cakes. That means the structure of the intermediate filament uniformity is better than the external wire cake.
(4)Compared with the traditional ACW POY spinning process, the WINGS POY spinning system gathers the guide wire roller, network air nozzles and other components to the winding head, makes the spinning length significantly reduced, also reduce the disturbance caused by air flow inside the shop. The angle of tow coated with wire guide hook is reduced. That reduces the contact area of tow with the guide wire roller, and the impact of mechanical vibration. Making the filament rolls at the same spinning position has more even structure. The difference is less than the traditional ACW POY spinning process between different filament roll spun at coaxial winding. The mechanical properties are superior to the traditional process. Coefficient of variation of the experimental values of WINGS POY system are lower than the traditional ACW POY system. The quality of WINGS POY process product is superior to the traditional process.
引文
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