WO2006060523A1 - Procedes continus de fabrication de fibres composites - Google Patents
Procedes continus de fabrication de fibres composites Download PDFInfo
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- WO2006060523A1 WO2006060523A1 PCT/US2005/043392 US2005043392W WO2006060523A1 WO 2006060523 A1 WO2006060523 A1 WO 2006060523A1 US 2005043392 W US2005043392 W US 2005043392W WO 2006060523 A1 WO2006060523 A1 WO 2006060523A1
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- WO
- WIPO (PCT)
- Prior art keywords
- solution
- polymer
- aramid
- anisotropic
- isotropic
- Prior art date
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- 239000000835 fiber Substances 0.000 title claims abstract description 52
- 239000002131 composite material Substances 0.000 title claims abstract description 34
- 238000010924 continuous production Methods 0.000 title abstract description 8
- 229920000642 polymer Polymers 0.000 claims abstract description 83
- 238000000034 method Methods 0.000 claims abstract description 40
- 229920003235 aromatic polyamide Polymers 0.000 claims abstract description 33
- 239000004760 aramid Substances 0.000 claims abstract description 28
- 230000003068 static effect Effects 0.000 claims abstract description 11
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 19
- 239000002253 acid Substances 0.000 claims description 16
- 238000002156 mixing Methods 0.000 claims description 11
- 239000002904 solvent Substances 0.000 claims description 10
- -1 CISO3H Chemical compound 0.000 claims description 5
- 239000004677 Nylon Substances 0.000 claims description 4
- 229920001778 nylon Polymers 0.000 claims description 4
- UQSQSQZYBQSBJZ-UHFFFAOYSA-N fluorosulfonic acid Chemical compound OS(F)(=O)=O UQSQSQZYBQSBJZ-UHFFFAOYSA-N 0.000 claims description 3
- 229920001652 poly(etherketoneketone) Polymers 0.000 claims description 3
- 229920000767 polyaniline Polymers 0.000 claims description 2
- 229910005185 FSO3H Inorganic materials 0.000 claims 1
- 229920002292 Nylon 6 Polymers 0.000 claims 1
- 229920002302 Nylon 6,6 Polymers 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 5
- 230000003014 reinforcing effect Effects 0.000 abstract 1
- 239000000243 solution Substances 0.000 description 69
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 12
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 12
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 12
- 239000000203 mixture Substances 0.000 description 9
- 238000005406 washing Methods 0.000 description 9
- 239000003570 air Substances 0.000 description 7
- 238000012360 testing method Methods 0.000 description 6
- 238000012546 transfer Methods 0.000 description 5
- 150000001805 chlorine compounds Chemical class 0.000 description 4
- 230000001112 coagulating effect Effects 0.000 description 4
- 238000005345 coagulation Methods 0.000 description 4
- 230000015271 coagulation Effects 0.000 description 4
- 238000001125 extrusion Methods 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 239000012530 fluid Substances 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- CBCKQZAAMUWICA-UHFFFAOYSA-N 1,4-phenylenediamine Chemical compound NC1=CC=C(N)C=C1 CBCKQZAAMUWICA-UHFFFAOYSA-N 0.000 description 3
- WRDNCFQZLUCIRH-UHFFFAOYSA-N 4-(7-azabicyclo[2.2.1]hepta-1,3,5-triene-7-carbonyl)benzamide Chemical compound C1=CC(C(=O)N)=CC=C1C(=O)N1C2=CC=C1C=C2 WRDNCFQZLUCIRH-UHFFFAOYSA-N 0.000 description 3
- 150000007513 acids Chemical class 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 150000004985 diamines Chemical class 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 238000006386 neutralization reaction Methods 0.000 description 3
- 230000035882 stress Effects 0.000 description 3
- LXEJRKJRKIFVNY-UHFFFAOYSA-N terephthaloyl chloride Chemical compound ClC(=O)C1=CC=C(C(Cl)=O)C=C1 LXEJRKJRKIFVNY-UHFFFAOYSA-N 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- KEQGZUUPPQEDPF-UHFFFAOYSA-N 1,3-dichloro-5,5-dimethylimidazolidine-2,4-dione Chemical compound CC1(C)N(Cl)C(=O)N(Cl)C1=O KEQGZUUPPQEDPF-UHFFFAOYSA-N 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 229920006231 aramid fiber Polymers 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- XTHPWXDJESJLNJ-UHFFFAOYSA-N chlorosulfonic acid Substances OS(Cl)(=O)=O XTHPWXDJESJLNJ-UHFFFAOYSA-N 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 230000001143 conditioned effect Effects 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000010348 incorporation Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920003366 poly(p-phenylene terephthalamide) Polymers 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000010791 quenching Methods 0.000 description 2
- 230000002829 reductive effect Effects 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- WIFCKLPZYYALGY-UHFFFAOYSA-N 1h-pyrrole-2,3-dione Chemical compound O=C1NC=CC1=O WIFCKLPZYYALGY-UHFFFAOYSA-N 0.000 description 1
- ZZPLGBZOTXYEQS-UHFFFAOYSA-N 2,3-dichlorobenzene-1,4-dicarbonyl chloride Chemical compound ClC(=O)C1=CC=C(C(Cl)=O)C(Cl)=C1Cl ZZPLGBZOTXYEQS-UHFFFAOYSA-N 0.000 description 1
- ZBMISJGHVWNWTE-UHFFFAOYSA-N 3-(4-aminophenoxy)aniline Chemical compound C1=CC(N)=CC=C1OC1=CC=CC(N)=C1 ZBMISJGHVWNWTE-UHFFFAOYSA-N 0.000 description 1
- 239000004953 Aliphatic polyamide Substances 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 241000711573 Coronaviridae Species 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 241000364021 Tulsa Species 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 229920003231 aliphatic polyamide Polymers 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 235000006708 antioxidants Nutrition 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 150000004984 aromatic diamines Chemical class 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000002051 biphasic effect Effects 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000005191 phase separation Methods 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000012453 solvate Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 238000002166 wet spinning Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
- D01F6/90—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyamides
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
- D01F6/90—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyamides
- D01F6/905—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyamides of aromatic polyamides
Definitions
- This invention relates to continuous processes for making composite fibers.
- the invention relates to continuous processes for making composite fibers from aramid polymers.
- U.S. Patent 5,135,687 discloses a batch process for making a polyvinyl pyrroldione) [PVP]/p-phenylene terephthalamide [PPD-T] composite fiber.
- the process includes agitating an anisotropic mixture of acid solvent, aramid, and PVP; heating the agitated mixture to above its melting point; extruding the mixture through a spinneret, into and through a non-coagulating layer; and passing the extruded mixture into and through an aqueous coagulating bath.
- the mixture is heated with stirring for two hours at 85°C.
- Composite fibers made using aramids in conventional processes have desirable properties including tenacity, dyeability, thermal resistance and adhesion to elastomeric matrices.
- new and/or improved continuous processes for making composite fibers, particularly composite fibers made from aramid polymers, are desirable.
- the present invention is directed to these and other important ends.
- One aspect of the present invention is a process for making a composite fiber.
- the process includes: continuously combining an anisotropic polymer solution of an aramid polymer and an isotropic solution of a second polymer to form a combined polymer solution; passing the combined polymer solution through at least one static mixer to form a spin dope; and extruding the spin dope through a spinneret to form a composite fiber.
- the process further includes: passing the composite fiber through an air gap; contacting the composite dope fiber with a quench solution to form a coagulated composite fiber; contacting the coagulated composite fiber with a wash solution; contacting the washed composite fiber with a neutralization solution to form a neutralized and washed composite fiber; drying the neutralized and washed composite fiber; and winding up the dried composite fiber.
- the dried composite fiber can be wound onto a bobbin on a windup device.
- Figure 1 is a schematic illustration of one embodiment of a process for making composite yarn in accordance with the present invention.
- the present invention provides composite fibers of aramids and processes for the preparation of such fibers.
- the invention further relates to yarns, cords, fabrics, and articles incorporating the fibers, and processes for making such yarns, cords, fabrics, and articles.
- fiber is used herein interchangeably with "filament”, and means a relatively flexible, macroscopically homogeneous body having a high ratio of length to width across its cross-sectional area perpendicular to its length.
- the fiber cross section can be any shape, but is often somewhat circular.
- Fiber spun onto a bobbin in a package is referred to as continuous fiber. Fiber can be cut into short lengths called staple fiber. Fiber can be cut into even smaller lengths called floe. Multifilament yarns can be combined to form cords. Yarn can be intertwined and/or twisted.
- spin refers to the extrusion of a polymer solution through a spinneret.
- anisotropic solutions of polymers utilize anisotropic solutions of polymers.
- "Anisotropic" means having microscopic regions that are birefringent; that is, a bulk sample of an anistropic solution depolarizes plane polarized light because the light transmission properties of the microscopic regions of the solution (or polymer spin dope) vary with direction.
- Anisotropy in the polymer solutions and dopes used in the processes disclosed herein is due to the existence of at least part of the solution or dope in a liquid crystalline state.
- aramid is meant a polyamide wherein at least 85% of the amide (- CO-NH-) linkages are attached directly to two aromatic rings. Suitable aramid fibers are described in Man-Made Fibers-Science and Technology, Volume 2, Section titled Fiber-Forming Aromatic Polyamides, page 297, W. Black et al., lnterscience Publishers, 1968. Aramid fibers are, also, disclosed in U.S. Patent Nos. 4,172,938; 3,869,429; 3,819,587; 3,673,143; 3,354,127; and 3,094,511.
- Para-aramids are the primary polymers in aramid yarn fibers of this invention and poly(p-phenylene terephthalamide)(PPD-T) is the preferred para-aramid.
- PPD-T is meant the homopolymer resulting from mole-for- mole polymerization of p-phenylene diamine and terephthaloyl chloride and, also, copolymers resulting from incorporation of small amounts of other diamines with the p-phenylene diamine and of small amounts of other diacid chlorides with the terephthaloyl chloride.
- PPD-T means copolymers resulting from incorporation of other aromatic diamines and other aromatic diacid chlorides such as, for example, 2,6-naphthaloyl chloride or chloro- or dichloroterephthaloyl chloride or 3,4'-diaminodiphenylether. Preparation of PPD-T is described in U.S. Patent Nos. 3,869,429; 4,308,374; and 4,698,414.
- the isotropic solution of polymer can be made using any polymer selected from known flexible chain polymers, but preferred polymers are those that form isotropic solutions in mineral acids, including chlorosulfonic acid and fluorosulfonic acid, particularly sulfuric acid.
- a highly preferred polymer for use in the isotropic solution is PVP.
- suitable polymers include aliphatic polyamides (e.g., 6-nylon, 6,6-nylon, and 6,12- nylon), polyaniline, polyether ketone ketone (PEKK), aromatic polyamides (MPD-I, MPD-I/T), and copolymers of PVP, such as PVP/VA(Vinyl Acetate).
- the formation, during mixing, of droplets of sufficiently small size e.g., having average diameters of about 10 percent or less the magnitude of the diameter desired in a filament formed from the combined polymers, aids in the mixing of the anisotropic aramid solution and the isotropic polymer solution.
- the droplet size formed during mixing is less than about 5 percent of the desired filament diameter, more preferably less than about 2 percent of the desired filament diameter.
- a composite fiber can be prepared from PPD-T and a flexible chain polymer.
- a static mixer comprises a pipe having therein an arrangement of elements (plates) at varying angles with respect to the wall of the pipe.
- the plates provide shear and mixing as a material flows through the pipe.
- the number of plates can vary.
- An example of a suitable static mixer is a Sulzer type SMX, manufactured by Sulzer Chemtech, Tulsa, OK.
- Conditions and parameters for mixing can be determined by one skilled in the art. For purposes of example only, the following is provided.
- Homogeneity can be measured by a compositional uniformity coefficient of variation (CoV) with values between 5% and 0.1 %.
- CoV compositional uniformity coefficient of variation
- Lower CoVs are obtained by increasing mixer length.
- An anisotropic solution of an aramid polymer and an isotropic solution of a flexible chain polymer are not fully miscible and form a microscopically inhomogeneous system comprising small droplets that are generally not visible to the naked eye.
- a measurable parameter is drop size, also called particle size.
- the drop size can be set by a stress criterion and a strength parameter characteristic of the two polymer solutions, such as interfacial tension.
- An interfacial tension of about 10 dynes/cm is typical of organics in water, and can be used as a guideline or starting point.
- the static mixer can be designed to produce dispersed droplets of the isotropic solution within the anisotropic solution with an average diameter that can be as small as about 1/60 of the diameter of the composite fiber or smaller. It is generally desirable to minimize drop size.
- An equilibrium drop size is preferably obtained by the time the combined polymers have passed through a length in the mixer that is less than about 10 mixer diameters.
- the optimal dimensions of a static mixer can vary, depending upon the polymer solutions to be mixed, and in particular, on the viscosity and interfacial tension of the solutions. For example, for a pipe size of 0.815 inch (2.07 cm) inner diameter (ID) containing 18 mixer elements, a droplet size of about 0.45-1.3 microns has been estimated with a pressure drop of 407-141 psi (28.6-9.9 kg/cm 2 ).
- the droplet size is further reduced to an estimated diameter of 0.18-0.55 micron with a pressure drop of 594-205 psi (41.8-14.4 kg/cm 2 ).
- the pressure drop increases as the number of plates in the mixer increases, and as the diameter of the pipe decreases.
- One skilled in the art can adjust the diameter and/or number of plates to result in a desired droplet size at a given pressure drop.
- an aramid polymer 2 is dissolved in an acid solvent, such as sulfuric acid 4, to form an anisotropic solution of aramid polymer.
- the acid solvent is preferably concentrated, e.g., about 98-101%, typically 98-100.2%, sulfuric acid.
- Other acids that can be used include chlorosulfonic acid and fluorosulfonic acid.
- the anisotropic solution of aramid polymer preferably contains a high enough concentration of aramid polymer to form an acceptable filament after extrusion and coagulation.
- a practical minimum concentration of aramid polymer is that concentration that provides anisotropy in the solution. For example, a concentration of at least about 18 weight percent can be used.
- Yarn properties such as tenacity and modulus are affected in part by the polymer concentration of the anisotropic solution of aramid polymer, and the concentration can be adjusted to enhance desired properties. Generally, lowering the concentration below about 18 weight percent can cause a decrease in such properties.
- the polymer and acid for the anisotropic solution are mixed in a mixer 6 such as a twin-screw mixer, while being heated to an elevated temperature, e.g., 80 to 100 0 C for p-phenylene terephthalamide (PPD-T), to provide a solution 58 of the polymer in acid.
- a mixer 6 such as a twin-screw mixer
- an elevated temperature e.g. 80 to 100 0 C for p-phenylene terephthalamide (PPD-T)
- PPD-T p-phenylene terephthalamide
- the polymer solution is then transferred via transfer pump 8, to vessel 10, where it is deaerated under reduced pressure. Deaeration can be facilitated, e.g., by agitation.
- the solution 58 is then transferred via pump 12 through filter 14.
- an isotropic solution 60 is prepared by dissolving a flexible- chain polymer in acid, preferably the same acid as used in making the anisotropic solution.
- the isotropic solution preferably has a viscosity less than that of the anisotropic solution.
- the acid is first cooled to a frozen slurry before the flexible chain polymer is added in powder form.
- the anisotropic solution and the isotropic solution are maintained at about the same temperature after they are made and before they are combined. For example, for an anisotropic solution of poly p-phenyleneterephthalamide combined with an isotropic solution of PVP, the solutions are preferably maintained at a temperature of about 80 0 C prior to mixing.
- the isotropic solution 60 is prepared in mixer 18, then transferred using jacketed transfer lines via transfer pump 20 through filter 22 and into optional hold tank 24 and through stuffing pump 26 to injection pump 28 and injection valve 16.
- the isotropic solution 60 is injected into the anisotropic solution 58 to form a combined polymer solution 62.
- the combined polymer solution 62 is biphasic, due to immiscibility of the anisotropic solution of aramid polymer and the isotropic solution of flexible chain polymer.
- the combined polymer solution 62 is passed through at least one static mixer 30 and optional additional static mixer(s) 32 to form a mixed, combined polymer solution 64. In preferred embodiments, two mixers are used.
- the mixers are placed as to minimize the residence time (time between the initial combining of the solutions and extrusion from the spinneret) of the combined solutions.
- the residence time after mixing is less than 20 minutes, preferably less than 15 minutes, more preferably less than 10 minutes. More than two static mixers can be used, for example, to form smaller size droplets and/or to redisperse any agglomerated droplets.
- the mixed, combined polymer solution is then pumped via meter pump 34 to optional heat exchanger 36, to help control the temperature of the combined polymer solution.
- the concentration of aramid polymer in the mixed, combined polymer solution 64 is preferably high enough to provide a liquid-crystalline dope, preferably at least about 15 weight percent, more preferably at least about 16 weight percent.
- the maximum total concentration of polymers in the dope is limited primarily by practical factors, such as polymer solubility and dope viscosity.
- the concentration of total solids in the dope is preferably no more than about 22 weight percent, and more preferably no more than about 20 weight percent.
- Each polymer solution and/or the combined stream can contain additives such as anti-oxidants, lubricants, ultra-violet screening agents, colorants and the like which are commonly incorporated.
- the mixed, combined polymer solution 64 is extruded through spinneret 38 to form filament(s) 42.
- the spinneret 38 preferably contains a plurality of holes. The number of holes in the spinneret and their arrangement is not critical to the invention, but it is desirable to maximize the number of holes for economic reasons.
- the spinneret 38 can contain as many as 100 or 1000 or more, and they may be arranged in circles, grids, or in any other desired arrangement.
- the spinneret 38 can be constructed out of any materials that are resistant to the acids used in the process. Materials suitable for use in the spinnerets of the present process are disclosed, for example, in US Patents 4,137,032 and 4,054,468.
- Filaments 42 exiting the spinneret 38 enter gap 40 between the spinneret 38 and a coagulation bath (quench bath) 44 containing water, where the acid solvent is removed.
- the gap 40 is typically called an "air gap” although it need not contain air.
- the gap 40 can contain any fluid that does not induce coagulation or react adversely with the stream, such as air, nitrogen, argon, helium or carbon dioxide.
- spin stretch factor is the ratio of the velocity of a fiber as it exits the coagulating bath to the jet velocity. Jet velocity is the average velocity of the spinning dope exiting the spinneret as calculated from the volume of material passing through an orifice per unit time and the cross- sectional area of the orifice.
- the minimum spin stretch factor for use with a particular composition and orifice is that which allows the formation of a filament of relatively uniform denier and having desired physical properties.
- the practical upper limit of the spin stretch factor is preferably that at which breakage is eliminated.
- the filament then is passed via feed rolls 46 to wash station 48 and neutralization station 50. Then the filament is dried in dryer 52 to remove water.
- the temperature of the filament as it exits the dryer is typically 120°C to 220 0 C.
- the dryer residence time of the filament is typically several seconds. Finish is applied at finish applicator 54.
- the filament can be wound up onto a bobbin at windup device 56.
- the coagulated filament is washed in one or more wash steps to remove acid solvent from the filament.
- the washing and neutralization of the filament is preferably carried out in a continuous process by running the filament through a series of baths and/or through one or more washing cabinets.
- Washing cabinets typically comprise an enclosed cabinet containing one or more rolls which the filament travels around a number of times, and across, prior to exiting the cabinet. As the filament travels around the roll, it is sprayed with a washing fluid. The washing fluid is continuously collected in the bottom of the cabinet and drained therefrom.
- the temperature of the washing fluid(s) is preferably at least about 5°C, and preferably no greater than about 65°C, more preferably no greater than about 50 0 C. In a continuous process, the duration of the entire washing process which includes the time in the coagulation bath and in the washing bath(s) and/or cabinet(s) is sufficient to remove acid solvent from the spun filaments.
- Fibers made according to the processes disclosed herein can be used in any applications where fibers are used.
- composite fibers containing aramids made according to the processes disclosed herein can be used in yarn, cord (twisted yarn) or fabric form to provide reinforcement for a variety of matrices, including elastomers.
- the composite fibers, and yarns, cords and fabrics made therefrom, can be used in the manufacture of shaped articles, such as, for example, tires, belts and hoses.
- Denier is determined according to ASTM D 1577 and is the linear density of a yarn as expressed as weight in grams of 9000 meters of yarn. Denier times (10/9) is equal to decitex (dtex).
- the fibers to be tested are conditioned and then tested based on the procedures described in ASTM D885-98.
- Tenacity (breaking tenacity), elongation to break, and modulus of elasticity are determined by breaking test yarns on an lnstron tester. Tenacity is reported as breaking stress divided by linear density. Modulus is reported as the slope of the initial stress/strain curve converted to the same units as tenacity. Elongation is the percent increase in length at break. Both tenacity and modulus are first computed in g/denier units which, when multiplied by 0.8838, yield dN/tex units. Each reported measurement is the average of six breaks.
- Tensile properties for yarns are measured at 24° C and 55% relative humidity after conditioning under the test conditions for a minimum of 14 hours. Before testing, each yarn is twisted to a 1.1 twist multiplier. Each twisted specimen has a test length of 50 cm and is elongated at a rate of 50%/minute in an lnstron tester.
- HASR is a test to determine how much of its initial strength a yarn retains after heat aging. HASR is reported in percent of the breaking strength retained after exposure to controlled heat.
- a fresh yarn sample is conditioned at 24 0 C and 55% relative humidity for 14 hours.
- a portion of the sample is subjected to dry heat at a temperature of 24O 0 C for 3 hours and is then tested for tensile strength (Heat aged tenacity).
- a portion of the sample that has not been heated is also tested for tensile strength (As is tenacity).
- HASR 100 X [Heat aged tenacity]/[As is tenacity]
- An isotropic, 20 wt % solids solution of polyvinylpyrrolidone (PVP) in 100.1 % sulfuric acid was injected, by means of a diaphragm pump, into an anisotropic, 19.5 wt % solids solution of poly(p-phenyleneterephthalamide) in 100.1% sulfuric acid at a volumetric solution ratio (isotropic/anisotropic) of 'x ⁇ listed in Table 1.
- the resulting mixture was passed through a series of motionless Sulzer SMX mixers to intimately mix the two solutions.
- the first mixer had a pipe ID of 0.815 inch (2.07 cm) and was fitted with eighteen (18) removable mixing elements.
- the second mixer had an ID of 0.612 inch (1.55 cm) and was fitted with ten (10) mixing elements. Within about seven (7) minutes of passing through the second mixer, the resulting solution was extruded through a 667-hole spinneret having orifice diameters of 0.063 mm and spun using a conventional air gap-wet spinning process. The extruded solution was drawn through a 0.8 cm length air gap into an aqueous coagulating bath at 5 degrees C containing about 5% sulfuric acid. The resulting fiber was washed, neutralized and dried.
- Fibers of varying PVP content were produced depending on the volumetric ratio (isotropic/anisotropic) 'x 1 of the two polymer solutions. Yarn tensile properties are shown for several compositions in Table 1 derived from isotropic and anisotropic polymer solutions with solids concentrations of 20% and 19.5%, respectively.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Artificial Filaments (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
Abstract
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2007544487A JP2008522055A (ja) | 2004-12-01 | 2005-11-30 | 複合繊維を作製するための連続方法 |
CA2586635A CA2586635C (fr) | 2004-12-01 | 2005-11-30 | Procedes continus de fabrication de fibres composites |
BRPI0517126-1A BRPI0517126A (pt) | 2004-12-01 | 2005-11-30 | processos para a fabricação de uma fibra compósita |
CN2005800414171A CN101076622B (zh) | 2004-12-01 | 2005-11-30 | 制造复合纤维的连续方法 |
EP05852581A EP1825037B1 (fr) | 2004-12-01 | 2005-11-30 | Procedes continus de fabrication de fibres composites |
MX2007006390A MX2007006390A (es) | 2004-12-01 | 2005-11-30 | Procesos continuos para elaborar fibras compuestas. |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/001,432 | 2004-12-01 | ||
US11/001,432 US20060113700A1 (en) | 2004-12-01 | 2004-12-01 | Continuous processes for making composite fibers |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2006060523A1 true WO2006060523A1 (fr) | 2006-06-08 |
Family
ID=36177923
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2005/043392 WO2006060523A1 (fr) | 2004-12-01 | 2005-11-30 | Procedes continus de fabrication de fibres composites |
Country Status (9)
Country | Link |
---|---|
US (1) | US20060113700A1 (fr) |
EP (1) | EP1825037B1 (fr) |
JP (1) | JP2008522055A (fr) |
KR (1) | KR20070086810A (fr) |
CN (1) | CN101076622B (fr) |
BR (1) | BRPI0517126A (fr) |
CA (1) | CA2586635C (fr) |
MX (1) | MX2007006390A (fr) |
WO (1) | WO2006060523A1 (fr) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP4077506A1 (fr) * | 2019-12-20 | 2022-10-26 | Teijin Aramid B.V. | Procédé continu de recyclage |
Families Citing this family (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8100285B2 (en) * | 2007-03-09 | 2012-01-24 | Danielle Aseff | Food cooking, serving and storage device |
US11326277B2 (en) * | 2016-11-08 | 2022-05-10 | Teijin Aramid B.V. | Process for the manufacture of polyetherketoneketone fiber |
US11078627B2 (en) * | 2018-08-14 | 2021-08-03 | Dupont Safety & Construction, Inc. | High tensile strength paper suitable for use in electrochemical cells |
US11578461B2 (en) | 2020-03-17 | 2023-02-14 | Dupont Safety & Construction, Inc. | Papers comprising aerogel powder and aramid polymer fibrils |
US20210296685A1 (en) | 2020-03-17 | 2021-09-23 | Dupont Safety & Construction, Inc. | Solid-state composite electrolytes comprising aramid polymer fibrils |
EP4193016B1 (fr) | 2020-08-04 | 2024-07-17 | DuPont Safety & Construction, Inc. | Papier comprenant de la pâte aramide adaptée aux cellules électrochimiques, et des cellules électrochimiques fabriquées à partir de cette pâte |
WO2023038346A1 (fr) * | 2021-09-08 | 2023-03-16 | 코오롱인더스트리 주식회사 | Fibre discontinue de para-aramide, fils filés d'aramide et procédé de fabrication associé |
KR20240072178A (ko) | 2021-10-07 | 2024-05-23 | 듀폰 세이프티 앤드 컨스트럭션, 인크. | 기재 및 도포된 피브릴 커버링을 포함하는 부직포 시트 재료 |
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WO1992007120A1 (fr) * | 1990-10-15 | 1992-04-30 | E.I. Du Pont De Nemours And Company | Procede de melange de solutions d'additifs dans des courants de solutions de filage de para-aramide |
US5135687A (en) * | 1989-06-05 | 1992-08-04 | E. I. Du Pont De Nemours And Company | Process for making PVP/para-aramid fibers |
WO1996030569A1 (fr) * | 1995-03-30 | 1996-10-03 | Vserossiisky Nauchno-Issledovatelsky Institut Polymernykh Volokon S Opytnym Zavodom (Vniipv) | Solution a filer et fibres filees obtenues a partir de cette solution |
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US3673143A (en) * | 1970-06-24 | 1972-06-27 | Du Pont | Optically anisotropic spinning dopes of polycarbonamides |
US3869429A (en) * | 1971-08-17 | 1975-03-04 | Du Pont | High strength polyamide fibers and films |
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JPS53294A (en) * | 1976-06-23 | 1978-01-05 | Teijin Ltd | Preparation of aromatic polyamide with high degree of polymerization |
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US5011643A (en) * | 1989-04-13 | 1991-04-30 | E. I. Du Pont De Nemours And Company | Process for making oriented, shaped articles of para-aramid/thermally-consolidatable polymer blends |
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JPH11222718A (ja) * | 1998-02-09 | 1999-08-17 | Mitsubishi Rayon Co Ltd | 超極細アクリル系繊維集合体 |
US6436236B1 (en) * | 2001-03-05 | 2002-08-20 | E. I. Du Pont De Nemours & Company | Electrically-conductive para-aramid pulp |
DE10206103A1 (de) * | 2002-02-13 | 2003-08-21 | Basf Ag | Vorrichtung und Verfahren zur Herstellung von Formkörpern aus thermoplastischen Polymeren |
-
2004
- 2004-12-01 US US11/001,432 patent/US20060113700A1/en not_active Abandoned
-
2005
- 2005-11-30 KR KR1020077014930A patent/KR20070086810A/ko not_active Withdrawn
- 2005-11-30 CN CN2005800414171A patent/CN101076622B/zh active Active
- 2005-11-30 MX MX2007006390A patent/MX2007006390A/es active IP Right Grant
- 2005-11-30 EP EP05852581A patent/EP1825037B1/fr active Active
- 2005-11-30 BR BRPI0517126-1A patent/BRPI0517126A/pt not_active Application Discontinuation
- 2005-11-30 JP JP2007544487A patent/JP2008522055A/ja active Pending
- 2005-11-30 WO PCT/US2005/043392 patent/WO2006060523A1/fr active Application Filing
- 2005-11-30 CA CA2586635A patent/CA2586635C/fr active Active
Patent Citations (3)
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US5135687A (en) * | 1989-06-05 | 1992-08-04 | E. I. Du Pont De Nemours And Company | Process for making PVP/para-aramid fibers |
WO1992007120A1 (fr) * | 1990-10-15 | 1992-04-30 | E.I. Du Pont De Nemours And Company | Procede de melange de solutions d'additifs dans des courants de solutions de filage de para-aramide |
WO1996030569A1 (fr) * | 1995-03-30 | 1996-10-03 | Vserossiisky Nauchno-Issledovatelsky Institut Polymernykh Volokon S Opytnym Zavodom (Vniipv) | Solution a filer et fibres filees obtenues a partir de cette solution |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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EP4077506A1 (fr) * | 2019-12-20 | 2022-10-26 | Teijin Aramid B.V. | Procédé continu de recyclage |
Also Published As
Publication number | Publication date |
---|---|
EP1825037A1 (fr) | 2007-08-29 |
KR20070086810A (ko) | 2007-08-27 |
EP1825037B1 (fr) | 2012-02-29 |
US20060113700A1 (en) | 2006-06-01 |
CN101076622A (zh) | 2007-11-21 |
BRPI0517126A (pt) | 2008-09-30 |
CA2586635A1 (fr) | 2006-06-08 |
MX2007006390A (es) | 2007-06-20 |
JP2008522055A (ja) | 2008-06-26 |
CN101076622B (zh) | 2010-05-26 |
CA2586635C (fr) | 2012-05-22 |
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