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The core technology system and the whole production process of monofilament yarn

The application of polymer material science in monofilament manufacturing

The essence of monofilament yarn is the directional crystallization process of polymer materials. Taking polyester (PET), nylon 6 (PA6), and ultra-high molecular weight polyethylene (UHMWPE) as examples, the arrangement of their molecular chains directly determines the performance of the final product. Our laboratory data shows:

• When the molecular weight distribution is controlled at 1.8-2.2, the melt flow index can be stabilized at 12±0.5g/10min (230℃/2.16kg)
• For every 1% increase in crystallinity, the tensile strength can increase by 2.3-3.1MPa
• When the orientation degree reaches more than 85%, the elongation at break can be controlled in the ideal range of 15-18%

Key technical parameters of precision extrusion molding system

Our fifth-generation intelligent extrusion system adopts a two-stage screw design, and the specific technical features include:

• Compression ratio gradient control: feeding section 1:2.8 → metering section 1:1.2
• Temperature zoning management:
  • Zone 1: 265±1℃ (melting section)
  • Zone 2: 280±0.5℃ (homogenizing section)
  • Die head temperature: 275±0.3℃
• Melt pressure closed-loop control: ±0.2bar dynamic adjustment is achieved through piezoelectric sensors

Five core technological breakthroughs to improve strength

Dynamic control of multi-stage stretching process

• Using patented progressive stretching system to achieve:
• Pre-stretching ratio: 1:3.2 (temperature 85℃)
• Main stretching ratio: 1:4.5 (temperature 120℃)
• Forming stretching ratio: 1:1.05 (temperature 160℃)
• Real-time feedback adjustment through online laser diameter gauge (accuracy ±0.5μm) to ensure diameter fluctuation ≤1.2%

Industrial application of nano-enhancement technology

Introducing surface-modified SiO₂ nanoparticles (particle size 15-20nm) in the polymerization stage:

• When the addition amount is 0.3-0.5wt%, the elastic modulus increases by 18-22%
• Wear rate is reduced to 0.08mg/1000 times
• The interface bonding strength reaches 45MPa

Online defect detection and self-repair system

Configured with high-speed line scan camera (scanning frequency 20kHz) combined with AI algorithm:

• Surface defects ≥5μm can be identified
• The hot air compensation system completes local temperature compensation (±2℃) within 0.3 seconds
• The production scrap rate has dropped from the industry average of 1.8% to below 0.3%

Three major innovative directions for improving durability

Surface treatment technology with enhanced weather resistance

• Adopting atmospheric pressure plasma treatment (APP) system:
• Processing power: 5kW/m
• Oxygen flow rate: 25L/min
• The surface energy after treatment is increased to 72mN/m (water drop angle <15°). With nano zinc oxide anti-UV coating (thickness 200-300nm), it makes:
• The strength retention rate after 2000 hours of xenon lamp aging test is ≥92%
• Hydrolysis resistance (70℃/95%RH) increases the life by 3 times

Tribology optimization solution

Develop core-shell structure masterbatch technology:

• Core layer: polytetrafluoroethylene (PTFE) microspheres (particle size 0.5-1μm)
• Shell layer: maleic anhydride grafted compatibilizer
  Dynamic friction coefficient reduced from 0.35 to 0.18

Intelligent production quality traceability system

Generate an independent digital fingerprint for each production batch:

• Record 200+ process parameters
• Store 10TB/day of production data
• Achieve 15-minute reverse tracing of quality issues
  Predict equipment failures through machine learning, shorten maintenance response time by 70%