TECHNICAL FIELD
Present disclosure, in general, relates to field of metallurgy. More particularly the present disclosure relates to production of carbon filaments. Further, embodiments of the present disclosure discloses a melt spinning apparatus for producing the carbon filaments.
BACKGROUND OF THE DISCLOSURE
Carbon fibers possesses a unique combination of properties like low bulk density and high tensile strength and tensile modulus. These properties have made carbon fiber, a new age material for the application in many industries like automotive, aerospace, sporting goods, wind turbine. Polyacrylonitrile, commonly known as PAN is the most widely employed material for carbon fiber production. Further, other materials like petroleum pitch, coal tar pitch, and lignocellulosic materials are also employed for producing carbon fiber. Producing a suitable isotropic or mesophase precursor and spinning the said precursor to obtain green fiber are the key steps for carbon fiber production. Typically, for pitch based materials, melt spinning is widely employed to produce the carbon fiber. In this method, the precursor is at first melt above its glass transition temperature or the softening temperature in some cases and then extruded to produce the thread/filament like structure. A melt spinning apparatus and the melt spinning conditions play a key role in manufacturing the fibers.
The melt spinning machine is a machine for forming polymer melts or gels into filaments. The melt spinning machine includes an extruder to melt the polymer and pressurize the polymer. Further, the machine includes a melt pump which is configured to maintain a constant pressure on the melt. Further, the machine includes a spinning assembly which comprises of a distributer plate, a pressure plate, a filter pack and a spinneret. Further, the machine includes winders fixed at predefined locations to wind the filaments exiting the spinning assembly. However, the conventional melt spinning machines are complex in construction and required skilled labour for setting up the machine for operation. Furthermore, the conventional melt spinning machines, due to the complex configuration and large number of components have larger and complex flow path. The large and complex flow path generates high pressure drop which results in requirement of high pressure in the machine. The high pressure in-turn imparts high stresses on the melt material, which is undesired.

Present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the known arts.
SUMMARY OF THE DISCLOSURE
One or more shortcomings of the prior art are overcome by an apparatus as claimed and additional advantages are provided through the apparatus as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
In one non-limiting embodiment of the present disclosure, a melt spinning apparatus for producing carbon filaments is disclosed. The apparatus includes a furnace which is provisioned with at least one heater. Further, a container is accommodated in the furnace and configured to receive raw materials. The container is defined with at least one inlet port which is configured to receive an inert gas. Additionally, the apparatus includes at least one spinneret which is removably fixed to the container and is opposite to the at least one inlet port. The at least one spinneret is configured to receive the raw material. Furthermore, the apparatus includes one or more winders which are movably provisioned below to the at least one spinneret. The inert gas received in the container through the at least one inlet port is configured to pressurize the raw material and dispense the raw material through the at least one spinneret in form of filaments. The filaments dispensed through the at least one spinneret is adapted to be wound around the one or more winders.
In an embodiment, the apparatus includes a plurality of flanges that are provisioned at one end of the container which are defined with the at least one inlet port to receive the inert gas.
In an embodiment, the apparatus includes at least one outlet port defined in the plurality of flanges and is configured to channelize the inert gas out of the container.
In an embodiment, the at least one outlet port is fluidly connected to a pressure indicator and a regulator to regulate pressure of the inert gas within the container.
In an embodiment, the apparatus includes at least one feed port that is defined in the plurality of flanges and is configured to feed the raw materials into the container.

In an embodiment, the at least one feed port is adapted to receive at least one sensor to determine temperature within the container.
In an embodiment, the apparatus includes an end cap removably fixed at another end of the container opposite to the plurality of flanges. The end cap is configured to accommodate the at least one spinneret.
In an embodiment, the apparatus includes at least one distributor plate removably fixed upstream of the at least one spinneret in the end cap.
In an embodiment, the at least one distributor plate is defined with a plurality of holes oriented at predefined angles.
In an embodiment, the one or more winders are adapted to rotate at a speed of 200 RPM to 800 RPM.
In an embodiment, the one or more winders are configured to receive filaments at a predetermined angle to exert tension on filaments.
In an embodiment, the at least one heater is configured to melt the raw materials accommodated in the container.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiments when read in conjunction with the accompanying figures. One or more embodiments

are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
Fig. 1 illustrates a front view of the melt spinning apparatus, in accordance with an embodiment of the present disclosure.
Fig. 2 illustrates a sectional view of the furnace and the container within the furnace, in accordance with an embodiment of the present disclosure.
Fig. 3 illustrates a front view of a container positioned in a furnace, in accordance with an embodiment of the present disclosure.
Fig. 4 illustrates an exploded view of the container, in accordance with an embodiment of the present disclosure.
The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the device illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which forms the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that, the conception and specific embodiments disclosed may be readily utilized as a basis for modifying other apparatus, devices, systems and assemblies for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that, such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, to its system, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however,

that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non¬exclusive inclusions, such that a system or a device that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals have been used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to Figs. 1-4.
Fig. 1 illustrates a front view of a melt spinning apparatus (100) [hereafter referred to as apparatus (100)] for producing filaments. In an embodiment, the filaments may be including but not limited to carbon filaments, polymer filaments and the like which may be employed to produce or manufacture fibers. The apparatus (100) may include a frame (18). The frame (18) may include a plurality of supporting members (18a) stacked one above the other. Furthermore, the apparatus (100) may include a furnace (11) which may be provisioned in the frame (18) and may be supported by at least one supporting member (18a) of the plurality of supporting member (18a).
Referring to Fig. 2, the furnace (11) may be defined with a cavity to receive and accommodate a container (2) which may be configured to receive pitch based precursor such as petroleum or coal tar pitch [hereafter referred to as raw material]. In an embodiment, the at least one raw material may be added to the container (2) in solid form. Further, the furnace (11) may be provisioned with at least one heater (11a). The at least one heater (11a) may be located at predefined locations around the container (2) and may be configured to heat the container (2) such that the raw materials stored within the container (2) may melt and attain a liquid or a semi-liquid state. In an embodiment, the at least one heater (11a) may be including but not limited to heating coils and the like, which may be configured to produce heat. Furthermore, the remaining portion of the furnace

(11) may be filled with an insulation material (11b) which may be configured to insulate the container (2) accommodated within the furnace (11).
Referring now to Figs. 2, 3 and 4, the apparatus (100) may include a plurality of flanges (1, 6) which may be provisioned at one end of the container (2). The plurality of flanges (1, 6) may include a top flange (6) and a bottom flange (1). In an embodiment, the bottom flange (1) may be permanently fixed to one end of the container (2) and the top flange (6) may be removably fixed to the bottom flange (1) to seal the container (2). The plurality of flanges (1, 6) may also include a gasket (8) that may be positioned between the top flange (6) and the bottom flange (1) and may be configured to prevent leakage in the plurality of flanges (1, 6). Further, a plurality of fasteners (7) may be employed to fasten the top flange (6) and the bottom flange (1) together. Additionally, the top flange (6) or the bottom flange (1) may be defined with at least one support braces (9) which may extend from a flange body. The at least one support braces (9) may be configured to engage with at least one support member of the plurality of support member to support the container (2).
Further, the container (2) or the plurality of flanges (1, 6) may be defined with at least one feed port (23) [as seen in Fig. 4]. The at least one feed port (23) may be configured to receive the raw material and feed the raw material into the container (2). Additionally, the at least one feed port (23) may be adapted to receive at least one sensor (10) to determine temperature within the container (2) [as seen in Fig. 2]. The at least one sensor (10) may be including but not limited to a thermometer, a thermocouple, a thermowell and the like.
Furthermore, the container (2) or the plurality of flanges (1, 6) may defined with at least one inlet port (21) [as seen in Fig. 4]. The at least one inlet port (21) may be configured to receive inert gas such but not limited to Nitrogen or Argon and fill the gas into the container (2). The at least one inlet port (21) may be connected to an inlet conduit (12) [as seen in Fig. 3] which may be configured to supply the inert gas to the at least one inlet port (21). Further, the inlet conduit (12) may include an inlet valve (17) which may be positioned downstream of the at least one inlet port (21). The inlet valve (17) may be configured to selectively allow and restrict flow of inert gas in the inlet conduit (12).

In an embodiment, the inert gas fed into the container (2) may be a pressurized inert gas configured to exert pressure on the raw material that may be stored in the container (2). The pressure exerted on the raw material may be in the range of 0.2 to 5 bar.
Additionally, the container (2) or the plurality of flanges (1, 6) may be defined with at least one outlet port (22) [as seen in Fig. 4]. The at least one outlet port (22) may be configured to channelize the inert gas out of the container (2). The at least one outlet port (22) may be connected to an outlet conduit (20) [as seen in Fig. 3] which may be configured to receive the inert gas channelized out of the at least one outlet port (22). Further, the outlet conduit (20) may be fluidly connected to a pressure indicator (19) which may be adapted to indicate the pressure of the inert gas. Furthermore, a regulator (16) may be positioned downstream of the pressure indicator (19) which may be configured to regulate the pressure of the inert gas channelized in the container (2). The apparatus (100) may further include a relief valve (14) fluidly connected to the outlet conduit (20). The relief valve (14) may be configured to control or limit the pressure of inert gas in the apparatus (100). The pressure may be relieved by allowing the pressurized inert gas to flow from the outlet conduit (20) or the apparatus (100). The relief valve (14) may be configured to open when the pressure in the apparatus (100) exceeds a predefined pressure. Further, the apparatus (100) may include an isolation valve (15) which may be fluidly connected in the outlet conduit (20). The isolation valve (15) may be configured to selectively allow and restrict flow of inert gas in the outlet conduit (20).
Referring again to Figs. 2 and 4, the apparatus (100) may include an end cap (3). The end cap (3) may be removably fixed at another end of the container (2) opposite to the plurality of flanges (1, 6). The end cap (3) may be configured to accommodate at least one distributor plate (5) and at least one spinneret (4). The at least one distributor plate (5) may be removably fixed upstream of the at least one spinneret (4) in the end cap (3). The at least one distributor plate (5) may be defined with a plurality of holes oriented at predefined angles. In an embodiment, the predefined angles of the holes in the distributor plate (5) may range from 1000 – 1300. The at least one distributor plate (5) may be adapted to receive the melted raw material and distribute the melted raw material to be received by the at least one spinneret (4). Furthermore, the at least one spinneret (4) may be defined with one or more holes based on requirement. The at least one spinneret (4) may be configured to receive the melted raw material and dispense the melted raw material in the form of filaments. In an embodiment, the one or more holes in the at least one spinneret (4) may be defined with a

stepped profile where entry angles () may be in the range of 1000 - 1300. Further, the at least one spinneret (4) may be defined with a hole diameter (d) and an entry diameter (d_e) that may be related as 5d < d_e. Furthermore, a capillary length in the at least one spinneret (4) may be defined min the range of 2d-10d. In an embodiment, the at least one spinneret (4) may be defined with the one or more holes having diameter in the range of 100 to 1000 microns.
Referring back to Fig. 1, the apparatus (100) may include one or more winders (13). The one or more winders (13) may be movably positioned below the furnace (11) and the container (2), that is, the one or more winders (13) may be movably positioned below the at least one spinneret (4) and the end cap (3) to receive the filaments. The one or more winders (13) may be movably fixed on at least one supporting member (18a) in the frame (18) of the apparatus (100). The displacement of the one or more winders (13) may enable the one or more winders (13) to be positioned at required location on the plurality of supporting member (18a) such that the filaments from the at least one spinneret (4) may be received on the one or more winders (13) at a predetermined angle (α). The predetermined angle at which the filaments may be received on the one or more winders (13) may provide the required tension for melt spinning to filaments. In an embodiment, the one or more winders (13) may be adapted to rotate at a speed of 200 RPM to 800 RPM.
In an embodiment, the apparatus (100) may be adapted to receive fluids other than inert gas to pressurize the raw material.
It should be noted that in an exemplary embodiment, as seen in the Figs. 1-4 the construction, profile, arrangement, layout and connections of the apparatus (100) should not be construed as a limitation as the apparatus (100) may include any other type of construction, profile, arrangement, layout and connection or any other combinations for producing filaments.
In an operational embodiment, as seen in Figs. 1-4, the apparatus (100) may be utilized to produce carbon filaments which may be used for carbon fiber production. The raw material with predefined quantity may be filled into the container (2) through the at least one feed port (23). Upon feeding the raw material, the at least one feed port (23) may be closed by inserting the at least one sensor (10). Further, the furnace (11) may be switched ON and the at least one heater (11a) may be adapted to heat the raw material stored in the container (2). The heat from the at least one heater

(11a) may melt the raw material into liquid or semi-liquid form. Furthermore, the inert gas may be fed into the container (2) at predefined pressure from the inlet port (21). The inert gas, within the container (2) may be adapted to exert force on the melted raw material and pressurize/force the raw material towards the end cap (3). The pressurized melted raw material may be received by the at least one distributor plate (5). The distributed raw material may then be received by the at least one spinneret (4) which may be adapted to dispense the melted raw material in the form of filaments. The dispensed filaments may be received and wound around the one or more winders (13) such that the filaments wound around the one or more winder (13) may be further processed as per requirement. This way, the apparatus (100) may be adapted to produce filaments with less number of components and define a shorter and simple flow path for the raw material to flow.
In an embodiment, the filaments dispensed from the at least one spinneret (4) may be configured to cool and solidify before being wound around the one or more winders (13).
In an embodiment, the frame (18) may include means (for example, wheels) for displacing the apparatus (100) and enable portable melt spinning operations.
In an embodiment, the apparatus (100) may include a housing which may be configured to cover the frame (18) and components to secure the apparatus (100).
In an embodiment, the apparatus (100) is simple to construct and easy to maintain. Further, the simple configuration of the apparatus (100), facilitates setting up of the apparatus (100) without the need for skilled labour and reduces the time required for setting up.
In an embodiment, short and simple flow path for the raw materials in the apparatus (100) eliminates high pressure drop during flow and does not require high pressure generating equipment which increases the complexity and cost of the apparatus (100). Further, as high pressures is not required by the apparatus (100) high stresses are not exerted on the raw material.
It should be imperative that the construction and configuration of the apparatus and any other elements or components described in the above detailed description should not be considered as a limitation with respect to the figures. Rather, variation to such structural configuration of the elements or components should be considered within the scope of the detailed description.

Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in

general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims.

Referral Numerals:
Reference Number Description
100 Apparatus
1 Bottom flange
2 Container
3 End cap
4 Spinneret
5 Distributor plate
6 Top flange
7 Fastener
8 Gasket
9 Support brace

10 Sensor
11 Furnace
11a Heater
11b Insulation material
12 Inlet conduit
13 Winder
14 Relief valve
15 Isolation valve
16 Regulator
17 Inlet valve
18 Frame
18a Supporting member
19 Pressure indicator
20 Outlet conduit
21 Inlet port
22 Outlet port
23 Feed port

We Claim:
1. A melt spinning apparatus (100) for producing carbon filaments, the apparatus (100)
comprising:
a furnace (11) provisioned with at least one heater (11a);
a container (2) accommodated in the furnace (11) and configured to receive raw materials, wherein the container (2) is defined with at least one inlet port (21) configured to receive an inert gas;
at least one spinneret (4) removably fixed to the container (2) opposite to the at least one inlet port (21), wherein the at least one spinneret (4) is configured to receive the raw material; and
one or more winders (13) movably provisioned below to the at least one spinneret (4);
wherein the inert gas is configured to pressurize the raw material and dispense the raw material through the at least one spinneret (4) in form of filaments adapted to be wound around the one or more winders (13).
2. The apparatus (100) as claimed in claim 1, comprises a plurality of flanges (1, 6) provisioned at one end of the container (2), wherein the plurality of flanges (1, 6) are defined with the at least one inlet port (21) to receive the inert gas.
3. The apparatus (100) as claimed in claim 2, comprises at least one outlet port (22) defined in the plurality of flanges (1, 6) configured to channelize the inert gas out of the container (2).
4. The apparatus (100) as claimed in claim 3, wherein the at least one outlet port (22) is fluidly connected to a pressure indicator (19) and a regulator (16) to regulate pressure of the inert gas within the container (2).
5. The apparatus (100) as claimed in claim 2, comprises at least one feed port (23) defined in the plurality of flanges (1, 6) configured to feed the raw materials into the container (2).

6. The apparatus (100) as claimed in claim 5, wherein the at least one feed port (23) is adapted to receive at least one sensor (10) to determine temperature within the container (2).
7. The apparatus (100) as claimed in claim 1, comprises an end cap (3) removably fixed at another end of the container (2) opposite to the plurality of flanges (1, 6), wherein the end cap (3) is configured to accommodate the at least one spinneret (4).
8. The apparatus (100) as claimed in claim 6, comprises at least one distributor plate (5) removably fixed upstream of the at least one spinneret (4) in the end cap (3).
9. The apparatus (100) as claimed in claim 7, wherein the at least one distributor plate (5) is defined with a plurality of holes oriented at predefined angles.
10. The apparatus (100) as claimed in claim 1, wherein the one or more winders (13) are adapted to rotate at a speed of 200 RPM to 800 RPM.
11. The apparatus (100) as claimed in claim 1, wherein the one or more winders (13) configured to receive filaments at a predetermined angle to exert tension on filaments.
12. The apparatus (100) as claimed in claim 1, wherein the at least one heater (11a) is configured to melt the raw materials accommodated in the container (2).