Factors Affecting the Uniformity of PET Flagged Filaments
The uniformity of PET flagged filaments is crucial for products such as industrial brushes and cosmetic brushes. Several key factors influence this uniformity:
- Raw Materials
Purity of PET Resin: The purity of PET resin should be ≥99.5%. Instability during melting can lead to significant variations in filament strength and diameter. If the filament diameter deviates beyond ±0.01mm or has irregular cross-sections, it can result in uneven flocking due to inconsistent stress distribution.
Pre-treatment Conditions: Uneven heating during thermal stabilization or the presence of surface oils can negatively impact filament elasticity or cause fiber clumping.
- Production Process
Flocking Machine Settings: The density and speed of the combing teeth must be compatible with the flagged filaments. Mismatches can lead to over-flocking or missed areas.
Feeding Speed and Tension: Inconsistent feeding speed and tension can cause fiber clumping or sparse distribution. Coarse filaments may require 2-3 passes to achieve even flocking, and dull cutting blades or uneven platforms can create variations in fiber length.
- Equipment Condition
Wear and Alignment of Combing Rolls: If the combing teeth wear down more than 0.1mm or have a misalignment greater than 0.02mm, this can create blind spots in the flocking process.
Tension Control System: Low sensitivity in the tension control system and significant air pressure fluctuations can disrupt tension stability. Accumulation of debris in the gaps between combing teeth or lack of lubrication in moving parts can also interfere with feeding and speed.
- Environmental Conditions
Temperature: The optimal temperature range is 20-25°C. Excessively high temperatures can cause the filaments to become soft and tangled, while excessively low temperatures can make them brittle.
Humidity Levels: Humidity must be maintained at appropriate levels; too low can create static electricity, while too high can cause clumping in the combing teeth. High levels of airborne impurities can obstruct the combing process and form clumps of contaminants.
To achieve and maintain consistent uniformity in flagged filaments, companies should implement standardized controls throughout the entire process.
