DESC:FIELD
The present disclosure relates to the field of polymer engineering. Particularly, the present disclosure relates to a spinneret plate for extruding fibers therefrom.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicate otherwise.
Denier – the term ‘denier’ hereinafter in the specification refers to weight per unit length measure of a continuous filament or yarn.
Perforated portion – The term ‘perforated portion’ hereinafter in the specification refers to the part of the spinneret plate that defines perforations and has a top face on upstream side and a bottom face on downstream side and has a reduced thickness.
Perforations – The term ‘perforations’ or capillaries hereinafter in the specification refers to no. holes configured on the spinneret plate that extend from the top face of the spinneret plate to the bottom face or extrusion face of the spinneret plate.
Annular collar – The term ‘annular collar’ hereinafter in the specification refers to part integral with the perforated portion and configured downstream side of the spinneret plate, and having a slot on outer periphery to fit said spinneret plate on pack filter body.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Typically, a spinneret plate has a plurality of holes or capillaries configured thereon to extrude polymeric fibers therefrom. Conventionally, the thickness of the spinneret plate is approximately in the range of 20 mm to 24 mm. This thickness is fixed irrespective of the thickness of a fibre or fibres to be extruded from the spinneret plate and the number of holes to be configured on the spinneret plate. Further, the spinneret plate has a top face and a bottom face. The bottom face is generally exposed or open to atmosphere and the top face is at a temperature around 300°C and above. This results in a temperature difference of approximately 260°C to 300°C. The temperature difference across the spinneret plate further results in the loss of heat across the spinneret plate, thereby affecting the spinning productivity. Moreover, the temperature difference between the top face and the bottom face (extrusion face) of the spinneret plate is controlled by varying the thickness of the spinneret plate. More particularly, the temperature difference across the spinneret plate is inversely proportional to the thickness of the spinneret plate.
As described herein above, the bottom face of the spinneret plate is exposed to atmosphere, i.e., the temperature of the bottom face is significantly less as compared to the top face of the spinneret plate. This result in increasing the temperature difference between the top and bottom faces; and spin line stresses. Further, increase in the spin line stresses causes breaking of filaments, thereby decreasing the spinning productivity.
There is, therefore, felt a need for an alternate spinneret plate with a reduced thickness that alleviates the aforementioned drawbacks of the conventional spinneret plate.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide an alternate spinneret plate that is capable of decreasing the temperature difference between a top face and a bottom face of the spinneret plate.
Another object of the present disclosure is to provide an alternate spinneret plate that facilitates increasing a spinning productivity.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a spinneret plate for extruding fibers therefrom. The spinneret plate of the present disclosure comprises a perforated portion defining perforations; an annular collar integral with the perforated portion, the annular collar configured downstream side of spinneret plate, and having a slot on outer periphery to fit the spinneret plate on pack filter body; and the perforated portion has a predetermined thickness configured to decrease the temperature difference between a top face and a bottom face of the spinneret plate. The top face is defined on upstream side of the perforated portion and the bottom face is defined on downstream side of perforated portion. The pre-determined thickness of the perforated portion is in the range of 3 mm to 17 mm. The perforations extend from the top face to the bottom face and the perforations are configured in at least one pattern selected from the group consisting of concentric circles, parallel and diamond on the spinneret plate for extrusion of fibers from the perforations.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A spinneret plate for extruding fibers therefrom will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a schematic view of a spinneret plate in accordance with the present disclosure; and
Figures 2A – 2B depict the spinneret plate of Figure 1, having a provision for a collar.
Figure 2C illustrates a perspective view of the spinneret plate in accordance with the present disclosure.
LIST OF REFERENCE NUMERALS
100 – Spinneret Plate
10 – Perforated portion
20 – Perforations or capillaries
30 – Top face of spinneret plate
40 – Bottom face of spinneret plate
T1 – Pre-determined thickness of spinneret plate
T – Thickness of perforated portion
C – Collar of spinneret plate
S - Slot

DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a”, "an", and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises", "comprising", “including”, and “having” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on", “engaged to”, "connected to", or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner”, “outer”, "beneath", "below", "lower", "above", "upper", and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
The present disclosure, envisages a spinneret plate that facilitates controlling the temperature difference between a top face and a bottom face of the spinneret plate.
Referring to Figure 1, a spinneret plate (100), in accordance with an embodiment of the present disclosure, is shown. The spinneret plate (100) has a pre-determined thickness; and comprises a perforated portion (10) defining perforations (20); an annular collar (not shown in figure 1) integral with the perforated portion (10), the annular collar is configured downstream side of the spinneret plate (100), and is having a slot (not shown in figure 1) on outer periphery to fit the spinneret plate (100) on pack filter body.
The perforated portion (10) has a predetermined thickness (T) configured to decrease the temperature difference between a top face (not shown in figure 1) and a bottom face (not shown in figure 1) of said spinneret plate (100). The perforated portion (10) has a pre-determined diameter configured thereon. Particularly, the perforated portion core (10) extends from the top face of the spinneret plate (100) to the bottom face or extrusion face of the spinneret plate (100). The pre-determined diameter of the perforated portion (10) is in the range of 30 mm to 100 mm.
A plurality of capillaries or perforations (20) is configured on the spinneret plate (100). Particularly, perforations (20) extend from the top face to the bottom face or extrusion face of the spinneret plate (100). The perforations or capillaries (20) (holes) can be arranged in at least one pattern selected from the group consisting of concentric circles, parallel and diamond.
The temperature of spinneret plate (100) also depends upon the throughput and number of holes (20), but upto a certain extent that is increasing throughput increases the extrusion face temperature upto a certain denier. In accordance with the present disclosure, depending upon the throughput per hole and the number of holes configured on the spinneret plate (100), the temperature difference can be approximately in the range of 3 °C to 20 °C. Number of perforations or capillaries (20) improves the temperature distribution across the surface of spinneret plate (100). But, for present disclosure the throughput of the plurality of holes (20) with has negligible effect on temperature difference between the top face and bottom face of the spinneret plate (100).
The diameter of the spinneret plate (100) is in the range of 50 mm to 350 mm.
The pre-determined thickness (T1) of the spinneret plate (100) is in the range of 18 mm to 24 mm.
Preferably, the pre-determined thickness (T) of perforated portion (10) is in the range of 3 mm to 17 mm.
Referring to Figure 2A-2B, the spinneret plate (100) is provided with a provision of an annular collar (C). The annular collar (C) integral with the perforated portion (10). The annular collar (C) is configured downstream side of the perforated portion (10), and having a slot (S) on outer periphery to fit said spinneret plate (100) on pack filter body. The slot (S) is received by a protrusion provided on the pack filter body for securing or fitting the spinneret plate (100) on the pack filter body, thereby ensuring an appropriate alignment of the spinneret plate (100). The pre-determined thickness (T) between the top face (30) and bottom face or extrusion face (40) is shown in Figure 2A. The bottom face (40) is also shown in figure 2 A.
Referring to Figure 2C, a perspective view of the spinneret plate (100) along with collar (C) having slot (S) is illustrated.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
Experimental details:
Experiment 1 (comparative):
Polymer fibers were extruded using a conventional spinneret plate having a diameter of 100 mm and thickness of 24 mm. The winding speed was taken to be 2550 mpm. The temperatures at the top face and bottom face of the spinneret plate were measured and were found to be 285 and 274 degree C approximately.
The properties of the polymer fiber so obtained are listed in table 1 below:

Table 1
Conventional Spinneret 24mm thickness; Winding Speed 2550 mpm
Properties Aim Avg.
Denier 243.0 241.8
% Elongation 141.0 139.3
Tenacity 2.70 2.57

Experiment 2 (in accordance with the present disclosure):
Polymer fibers were extruded using spinneret plates A to C having 100 mm diameter and thickness 5 mm, 9 mm and 15 mm respectively. For respective spinneret plates A, B, and C with different thickness as mentioned above, winding speeds were 2690 mm, 2650 mm and 2580 mpm, respectively. The respective temperatures for the spinneret plates A to C at the top face and bottom face of the spinneret plate were measured and are listed in table 2 below.
The properties of the polymer fiber so obtained along with the dimension and temperatures of the top and bottom face are listed in table 2 below:
Table 2
A B C
Properties Aim Avg. Aim Avg. Aim Avg.
Denier 243.0 241.8 243.0 241.9 243.0 242.1
% Elongation 141.0 139.7 141.0 139.9 141.0 139.5
Tenacity 2.70 2.55 2.70 2.56 2.70 2.58
Spinneret plate details
Temperature (at Top Face) 285 285 285 285 285 285
Temperature (at Bottom Face) 282 282 277 277 278 278
Thickness (perforated portion) 5mm 5mm 9mm 9mm 15mm 15mm
Spinning Speed mpm 2690 2690 2650 2650 2580 2580

By comparing data provided in Table 1 and Table 2 it is evident that with increase in thickness of the perforated portion the temperature difference between the top face and the bottom face increases from 3 degrees to 7 degrees. With increase in temperature difference between the top face and the bottom face of respective spinneret plates the % elongation of the fibers being extruded from perforations of the respective spinneret plates A to C varied slightly that is 139.7, 139.9 and 139.5. Tenacity for respective spinneret plates A to C increased from 2.55 to 2.58.
In accordance with the present disclosure, reducing the thickness of the spinneret plate (100) facilitates increase in the productivity (extrusion) of the polymeric fibers from the spinneret plate (100) by approximately 4 percent, as compared to that of the conventional spinneret plate (without reducing the thickness).

TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a spinneret plate:
• having a perforated portion with a pre-determined thickness that facilitates decrease in the thickness of the spinneret plate, which in turn facilitates in decreasing the temperature difference between the top face and the bottom face of the spinneret plate.
• having a decreased temperature difference between the top face and the bottom face of the spinneret plate increases extrusion efficiency of the polymeric fibers from the spinneret plate or the spinning productivity.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:
1. A spinneret plate (100) comprising:
a perforated portion (10) defining perforations (20);
an annular collar (C) integral with said perforated portion (10), said annular collar (C) configured downstream side of said spinneret plate (100), and having a slot (S) on outer periphery to fit said spinneret plate (100) on pack filter body; and
said perforated portion (10) has a predetermined thickness (T) configured to decrease the temperature difference between a top face (30) and a bottom face (40) of said spinneret plate (100).
2. The spinneret plate (100) as claimed in claim 1, wherein said top face (30) is defined on upstream side of said perforated portion (10).
3. The spinneret plate as claimed in claim 1, wherein said bottom face (40) is defined on downstream side of perforated portion (10).
4. The spinneret plate as claimed in claim 1, wherein said pre-determined thickness (T) of said perforated portion (10) is in the range of 3 mm to 17 mm.
5. The spinneret plate (100) as claimed in claim 1, wherein said perforations (20) extend from said top face (30) to said bottom face (40).
6. The spinneret plate (100) as claimed in claim 5, wherein said perforations (10) are configured in at least one pattern selected from the group consisting of concentric circles, parallel and diamond on said spinneret plate (100) for extrusion of fibers from said perforations (20).