EP0339240A2 - Polyphenylene sulfide microfibres - Google Patents

Polyphenylene sulfide microfibres Download PDF

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Publication number
EP0339240A2
EP0339240A2 EP89104664A EP89104664A EP0339240A2 EP 0339240 A2 EP0339240 A2 EP 0339240A2 EP 89104664 A EP89104664 A EP 89104664A EP 89104664 A EP89104664 A EP 89104664A EP 0339240 A2 EP0339240 A2 EP 0339240A2
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EP
European Patent Office
Prior art keywords
fibers
melt
pps
fiber
temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP89104664A
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German (de)
French (fr)
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EP0339240A3 (en
Inventor
Peter-Roger Dipl.-Ing. Nyssen
Wolfram Dr. Wagner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NYSSEN, PETER, ROGER
Original Assignee
NYSSEN Peter Roger
Bayer AG
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Publication date
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Publication of EP0339240A2 publication Critical patent/EP0339240A2/en
Publication of EP0339240A3 publication Critical patent/EP0339240A3/en
Withdrawn legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/42—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments
    • D01D5/423—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments by fibrillation of films or filaments
    • 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
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/76—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from other polycondensation products
    • D01F6/765—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from other polycondensation products from polyarylene sulfides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/903—Microfiber, less than 100 micron diameter
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/609—Cross-sectional configuration of strand or fiber material is specified
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/626—Microfiber is synthetic polymer

Definitions

  • the invention relates to fibers, non-woven fabrics or fiber piles based on polyphenylene sulfide and methods for producing such products.
  • PPS fibers polyphenylene sulfide fibers
  • EP 171 021 fibers and filaments are produced from the polyarylene sulfides belonging to the polyphenylene sulfide group by melt spinning.
  • melts When working with PPS melts, it has also been found that such melts easily oxidize on the surface, which affects the product quality of the fibers produced by melt spinning.
  • polymer fibers based on PPS with an average fiber diameter of ⁇ 6 ⁇ m, preferably 0.2 ⁇ m to 6 ⁇ m are produced in that the polymer melt streams flow through an essentially parallel along a zone of 2 mm to 100 mm, preferably 2 mm to 50 mm, and at a lateral distance of 2 mm to 30 mm from the outlet bores sound or supersonic velocity reaching gaseous medium are extracted and cooled below the melt temperature, with simultaneous deformation and cooling amorphous fine or finest fibers of finite length arise, which are laid down to form a nonwoven or fiber pile.
  • melt streams are additionally substantially longitudinally by the action of one on the melt streams in a zone of 1 mm to 30 mm, preferably 2 mm to 10 mm, in connection with the outlet bores acting static pressure drop.
  • the fiber formation process is based on the one hand on a direct pressure drop and on the other hand on the acceleration due to the gaseous medium flowing in parallel.
  • the fibers produced in this way based on PPS obey a narrow Gaussian distribution with a coefficient of variation ⁇ 50%, preferably between 10% and 35% and a strength of 0.4 to 1.1 GPa and without thermal fixation have an elongation of 20 to 80% and, after thermal fixation under tension, a strength of 0.6 to 1.1 GPa and an elongation of 10% to 30%.
  • the process for producing such PPS fibers is characterized according to the invention in that polymer melt streams based on PPS emerging from spinning bores under the action of an inert gas flowing in parallel therewith at a temperature of 20 ° C to 280 ° C, preferably 80 ° C to 200 ° C, drawn out to finally long fine fibers and cooled below the melt temperature.
  • the fibers are expediently thermally fixed by the action of the hot inert gases immediately after the fiber formation process.
  • the fibers emerging from the drawing nozzle can subsequently be thermally fixed in several stages, preferably by thermal fixing by means of calenders or by inert gases at a temperature of 80 ° C. to 260 ° C.
  • the mechanical properties of the new PPS fibers are superior to the known PPS fibers. In particular, they have a higher tear resistance. These favorable properties are probably due to the fact that oxidation processes during spinning can largely be avoided due to the high cooling rate in the drawing nozzle.
  • PPS granules 2 are melted at a temperature of 320 ° C. by means of the extruder 1 and fed to the spinneret 5 at a pressure of 6 bar by means of the spinning pump 3 via the melt filter 4.
  • the melt has a viscosity of 50 Pas at this temperature.
  • the melt emerging from the outlet bores 6 of the spinning nipples 7 (FIG. 2 and FIG. 3) is drawn into very fine fibers in the gas-dynamic pulling nozzle 8 arranged below the spinneret 5 and deposited in the collecting chamber 9 on a conveyor belt 10 to form a nonwoven fabric 11.
  • a detailed explanation of the construction and the mode of operation of the drawing nozzle 8 can be found e.g. in EP 38 989 and EP 66 506.
  • a pressure drop along the axis of the drawing nozzle which is generated in a known manner by driving jets 12 (FIG. 2).
  • Compressed air with a temperature of 50 ° -100 ° C and a static pressure of 10 bar is used as the blowing agent, which is supplied via the connections 13.
  • Propellant and suction gas are drawn off below the storage chamber 9 and the conveyor belt 11 through the suction box 15.
  • the temperature of the spinneret 5 is kept constant at a value in the range from 300 ° C to 350 ° C.
  • the mass throughput per spinning bore is 2.5 g / min.
  • the fibers 11 obtained in this way have the fiber diameter distribution shown in FIG. 4 with an average fiber diameter of 4.1 ⁇ m and a coefficient of variation of 33%.
  • the ordinate is the sum of the frequencies of all occurring fiber diameters, each of which is below a fiber limit diameter shown on the abscissa. From this it can be seen that fibers with a diameter of ⁇ 2 ⁇ m and> 8 ⁇ m practically no longer exist.
  • Example 2 Also with the same apparatus and under the same conditions as in Example 1, a nonwoven fabric was produced, which was subjected to thermal fixation with hot inert gas after the fiber deposition. The fleece was exposed to temperatures of Exposed to 80 ° C to 260 ° C. These measures were also used to prevent material shrinkage.
  • the drawing nozzle method used in the above-described exemplary embodiments can also be modified in such a way that the melt flow is first defibrated by a high static pressure drop and then extracted again by a gas stream flowing in parallel (see FIG. 3).
  • the spinneret 5 forms a closed system together with the downstream drawing nozzle 8.
  • the melt 16 is fed to the spinning nipple 7 with the outlet bore 6 via a melt filter.
  • a sealed (18) closed pressure chamber 19 is arranged between the lower edge of the spinneret 5 and the upper edge of the drawing nozzle 8 in a rotationally symmetrical manner about the axis.
  • the pressure chamber which is closed on all sides, can be supplied with inert gas 20 under pressure.
  • the inert compressed gas was introduced into the pressure chamber 19 at a temperature of 350 ° C. and at an absolute pressure of 10 bar.
  • the fiber formation 17 then takes place directly in the pressure gradient and, furthermore, due to the gas flow resulting from the pressure gradient (greatest pressure in the pressure chamber 19) in the Laval nozzle 21 following the pressure chamber and the subsequent impact diffuser 22 instead.
  • the laying of the fibers 17 to the fleece 11 takes place in the same way as in the device according to FIGS. 1 and 2. With the operating conditions described above, using this variant, very fine fibers with an average fiber diameter of 0.6 ⁇ m and a standard deviation of 0. 4 ⁇ m.
  • a further process variant for the production of the PPS fibers according to the invention consists in that the melt streams emerging from the spinneret are blown at high speed essentially in the flow direction in a subsequent open space (free space) by hot air.
  • the drawing nozzle or Laval nozzle following the spinneret can be omitted.
  • the process is known under the name "melt blown process” and is e.g. in detail in U.S. Patent 4,048,364. It is particularly suitable for processing low-viscosity melts.
  • polyphenylene sulfide in the form of granules was used as the starting material.
  • Particularly suitable are the polyarylene sulfides belonging to the group of polyphenylene sulfides, the production and properties of which are described in more detail in EP 171 021.

Abstract

Fibres, nonwovens or loose heaps of fibres consisting of polyphenylene sulphide (PPS) or of mixtures of PPS with other polymers are produced by a melt spinning process, in which the melt filaments are drawn through a gaseous medium flowing essentially parallel thereto at the speed of sound or supersonic speed and are cooled below the melt temperature, amorphous fine or very fine fibres (17) of infinite length being formed by simultaneous deformation and cooling, which fibres are laid to form a nonwoven or loose heap of fibres. <IMAGE>

Description

Die Erfindung betrifft Fasern, Faservliese oder Faser­haufwerke auf der Basis von Polyphenylensulfid und Verfahren zur Herstellung solcher Produkte.The invention relates to fibers, non-woven fabrics or fiber piles based on polyphenylene sulfide and methods for producing such products.

Die Herstellung von Polyphenylensulfidfasern (PPS-­Fasern) durch Verspinnen einer PPS-Schmelze ist bekannt. Gemäß EP 171 021 werden aus den zur Stoffgruppe der Polyphenylensulfide gehörenden Polyarylensulfiden durch Schmelzspinnen Fasern und Filamente hergestellt.The production of polyphenylene sulfide fibers (PPS fibers) by spinning a PPS melt is known. According to EP 171 021, fibers and filaments are produced from the polyarylene sulfides belonging to the polyphenylene sulfide group by melt spinning.

Bisher sind jedoch keine aus Feinstfasern endlicher Länge bestehenden Faservliese oder Faserhaufwerke aus Polyphenylensulfid bekannt. Fasergebilde dieser Art können bekanntlich zu Matten oder Bahnen weiterver­arbeitet werden und haben vielfältige Anwendungsmög­lichkeiten.So far, however, no fibrous webs made of finest fibers of finite length or fiber piles made of polyphenylene sulfide are known. It is known that fiber structures of this type can be processed further into mats or webs and have a wide range of possible uses.

Beim Arbeiten mit PPS-Schmelzen hat sich auch heraus­gestellt, daß solche Schmelzen leicht an der Oberfläche oxidieren, wodurch die Produktqualität der durch Schmelzspinnen erzeugten Fasern beeinträchtigt wird.When working with PPS melts, it has also been found that such melts easily oxidize on the surface, which affects the product quality of the fibers produced by melt spinning.

Dieses Problem ist umso gravierender, je feiner die Fasern sind, d.h. je größer das Verhältnis von Ober­fläche zu Volumen ist.This problem is more serious the finer the fibers, i.e. the greater the ratio of surface to volume.

Hier setzt die Erfindung an. Es liegt die Aufgabe zu­grunde, aus Fein- bzw. Feinstfasern bestehende Vliese oder Haufwerke mit hoher Faserqualität durch eine ge­zielte Weiterverarbeitung der aus einer Spinndüse aus­tretenden Polymerschmelzeströme auf der Basis von reinem Polyphenylensulfid oder Mischungen von Polyphenylensul­fid mit anderen Polymeren (PPS-Polymerblends) herzustel­len. Dabei soll die oben erwähnte Beeinträchtigung der Faserqualität durch oberflächliche Oxidation soweit wie möglich ausgeschlossen werden.This is where the invention comes in. It is the object of the invention to produce nonwovens or piles of high fiber quality consisting of fine or very fine fibers by targeted further processing of the polymer melt streams emerging from a spinneret on the basis of pure polyphenylene sulfide or mixtures of polyphenylene sulfide with other polymers (PPS polymer blends). The above-mentioned impairment of fiber quality due to surface oxidation should be excluded as far as possible.

Diese Aufgabe wird erfindungsgemäß dadurch gelöst, daß Polymer-Fasern auf der Basis von PPS mit einem mittleren Faserdurchmesser <6 µm, vorzugsweise 0,2 µm bis 6 µm, dadurch erzeugt werden, daß die Polymer-Schmelzeströme durch ein im wesentlichen parallel dazu strömendes, längs einer Zone von 2 mm bis 100 mm, vorzugsweise 2 mm bis 50 mm, und in einem lateralen Abstand von 2 mm bis 30 mm von den Austrittsbohrungen Schall- oder Über­schallgeschwindigkeit erreichendes gasförmiges Medium ausgezogen und unter die Schmelzetemperatur abgekühlt werden, wobei durch gleichzeitige Deformation und Ab­kühlung amorphe Fein- bzw. Feinstfasern endlicher Länge entstehen, die zu einem Faservlies oder Faserhaufwerk abgelegt werden.This object is achieved according to the invention in that polymer fibers based on PPS with an average fiber diameter of <6 μm, preferably 0.2 μm to 6 μm, are produced in that the polymer melt streams flow through an essentially parallel along a zone of 2 mm to 100 mm, preferably 2 mm to 50 mm, and at a lateral distance of 2 mm to 30 mm from the outlet bores sound or supersonic velocity reaching gaseous medium are extracted and cooled below the melt temperature, with simultaneous deformation and cooling amorphous fine or finest fibers of finite length arise, which are laid down to form a nonwoven or fiber pile.

Eine Variante zur Erzeugung solcher Fasern besteht da­rin, daß die Schmelzeströme zusätzlich durch Einwirkung eines auf die Schmelzeströme im wesentlichen längs einer Zone von 1 mm bis 30 mm, vorzugsweise 2 mm bis 10 mm, im Anschluß an die Austrittsbohrungen einwir­kendes statisches Druckgefälle ausgezogen werden. Dem Faserbildungsprozeß liegt also hier einerseits ein direktes Druckgefälle und andererseits die Beschleuni­gung durch das parallel strömende gasförmige Medium zugrunde.A variant for the production of such fibers is that the melt streams are additionally substantially longitudinally by the action of one on the melt streams in a zone of 1 mm to 30 mm, preferably 2 mm to 10 mm, in connection with the outlet bores acting static pressure drop. The fiber formation process is based on the one hand on a direct pressure drop and on the other hand on the acceleration due to the gaseous medium flowing in parallel.

Fasern mit hoher Produktqualität kann man in vorteil­hafter Weise erhalten, wenn mit Schmelzen einer Spinn­viskosität von 2 Pas bis 250 Pas, vorzugsweise 80 Pas bis 150 Pas und mit einer Schmelzetemperatur von TS = 310°C gearbeitet wird.Fibers with high product quality can be obtained in an advantageous manner when working with melts having a spinning viscosity of 2 Pas to 250 Pas, preferably 80 Pas to 150 Pas and with a melt temperature of T S = 310 ° C.

Es wurde gefunden, daß die so erzeugten Fasern auf der Basis von PPS einer engen Gaußschen Verteilung mit einem Variationskoeffizient <50 %, vorzugsweise zwischen 10 % und 35 %, gehorchen und ohne thermische Fixierung eine Festigkeit von 0,4 bis 1,1 GPa und eine Dehnung von 20 bis 80 % und nach thermischer Fixierung unter Spannung eine Festigkeit von 0,6 bis 1,1 GPa und eine Dehnung von 10 % bis 30 % aufweisen. Das Verfahren zur Herstellung solcher PPS-Fasern ist erfindungsgemäß dadurch gekenn­zeichnet, daß aus Spinnbohrungen austretende Polymer-­Schmelzeströme auf der Basis von PPS unter der Einwir­kung eines parallel dazu strömenden Inertgases mit einer Temperatur von 20°C bis 280°C, vorzugsweise 80°C bis 200°C, zu endlich langen Feinfasern ausgezogen und unter die Schmelzetemperatur abgekühlt werden.It was found that the fibers produced in this way based on PPS obey a narrow Gaussian distribution with a coefficient of variation <50%, preferably between 10% and 35% and a strength of 0.4 to 1.1 GPa and without thermal fixation have an elongation of 20 to 80% and, after thermal fixation under tension, a strength of 0.6 to 1.1 GPa and an elongation of 10% to 30%. The process for producing such PPS fibers is characterized according to the invention in that polymer melt streams based on PPS emerging from spinning bores under the action of an inert gas flowing in parallel therewith at a temperature of 20 ° C to 280 ° C, preferably 80 ° C to 200 ° C, drawn out to finally long fine fibers and cooled below the melt temperature.

Zweckmäßig erfolgt durch Einwirkung der heißen Inertgase eine thermische Fixierung der Fasern direkt im Anschluß an den Faserbildungsprozeß.The fibers are expediently thermally fixed by the action of the hot inert gases immediately after the fiber formation process.

Alternativ können die aus der Ziehdüse austretenden Fasern nachträglich einer thermischen Fixierung mittels Kalander oder durch Inertgase mit einer Temperatur von 80°C bis 260°C vorzugsweise in mehreren Stufen thermisch fixiert werden.Alternatively, the fibers emerging from the drawing nozzle can subsequently be thermally fixed in several stages, preferably by thermal fixing by means of calenders or by inert gases at a temperature of 80 ° C. to 260 ° C.

Ferner hat sich herausgestellt, daß man Fasern bzw. Fa­serhaufwerke mit besonders geringer Schrumpfung erzeugen kann, wenn als Ausgangsmaterial für die Polymerschmelze Mischungen von PPS (PPS-Polymerblends) und Polybutylen­terephthalat mit einem Mischungsverhältnis von 2:1 bis 10:1, vorzugsweise 4:1 bis 8:1, verwendet werden.It has also been found that fibers or fiber piles with particularly low shrinkage can be produced if mixtures of PPS (PPS polymer blends) and polybutylene terephthalate with a mixing ratio of 2: 1 to 10: 1, preferably 4: 1, are used as the starting material for the polymer melt up to 8: 1.

Die neuen PPS- Fasern sind in ihren mechanischen Eigen­schaften den bekannten PPS-Fasern überlegen. Sie weisen insbesondere eine höhere Reißfestigkeit auf. Diese gün­stigen Eigenschaften sind wahrscheinlich darauf zurück­zuführen, daß Oxidationsprozesse beim Verspinnen auf­grund der hohen Abkühlgeschwindigkeit in der Ziehdüse weitgehend vermieden werden können.The mechanical properties of the new PPS fibers are superior to the known PPS fibers. In particular, they have a higher tear resistance. These favorable properties are probably due to the fact that oxidation processes during spinning can largely be avoided due to the high cooling rate in the drawing nozzle.

Im folgenden wird die Erfindung anhand von Zeichnungen und Ausführungsbeispielen näher erläutert. Es zeigen:

  • Figur 1 ein Verfahrensschema zur Herstellung von PPS-­Feinstfasern nach dem Ziehdüsenverfahren,
  • Figur 2 die Spinndüse und den Ziehdüseneintritt,
  • Figur 3 eine Vorrichtung, bei der die Faserbildung aufgrund eines statischen Druckgefälles und der Beschleunigung durch einen Gasstrom er­folgt und
  • Figure 4 eine typische Faserdurchmesserverteilung für die neuen PPS-Feinstfasern.
The invention is explained in more detail below with reference to drawings and exemplary embodiments. Show it:
  • FIG. 1 shows a process diagram for the production of PPS fine fibers by the drawing nozzle process,
  • FIG. 2 the spinneret and the drawing nozzle inlet,
  • Figure 3 shows a device in which the fiber formation takes place due to a static pressure drop and the acceleration by a gas stream and
  • Figure 4 shows a typical fiber diameter distribution for the new PPS fine fibers.

Beispiel 1example 1

Gemäß Figur 1 wird mittels des Extruders 1 PPS-Granulat 2 bei einer Temperatur von 320°C erschmolzen und mittels der Spinnpumpe 3 über den Schmelzefilter 4 der Spinndüse 5 mit einem Druck von 6 bar zugeführt. Die Schmelze be­sitzt bei dieser Temperatur eine Viskosität von 50 Pas. Die aus den Austrittsbohrungen 6 der Spinnippel 7 (Figur 2 und Figur 3) austretende Schmelze wird in der unter­halb der Spinndüse 5 angeordneten gasdynamischen Zieh­düse 8 zu Feinstfasern ausgezogen und in der Sammel­kammer 9 auf einem Transportband 10 zu einem Faservlies 11 abgelegt. Eine detaillierte Erläuterung des Aufbaus und der Wirkungsweise der Ziehdüse 8 findet sich z.B. in EP 38 989 und EP 66 506. Verantwortlich für den Zerfaserungs- und Auszieheffekt in der Ziehdüse 8 ist ein Druckgefälle längs der Achse der Ziehdüse, das in bekannter Weise durch Treibstrahlen 12 erzeugt wird (Figur 2). Als Treibmittel dient hier Druckluft mit einer Temperatur von 50°-100°C und einem Ruhedruck von 10 bar, die über die Anschlüsse 13 zugeführt wird. Auf­grund des Druckgefälles wird an der Ziehdüse atmosphä­rische Luft 14 mit einer Temperatur von 20°C bis 30°C angesaugt. Treibmittel und Sauggas werden unterhalb der Ablagekammer 9 und des Transportbandes 11 durch den Absaugkasten 15 abgezogen.According to FIG. 1, PPS granules 2 are melted at a temperature of 320 ° C. by means of the extruder 1 and fed to the spinneret 5 at a pressure of 6 bar by means of the spinning pump 3 via the melt filter 4. The melt has a viscosity of 50 Pas at this temperature. The melt emerging from the outlet bores 6 of the spinning nipples 7 (FIG. 2 and FIG. 3) is drawn into very fine fibers in the gas-dynamic pulling nozzle 8 arranged below the spinneret 5 and deposited in the collecting chamber 9 on a conveyor belt 10 to form a nonwoven fabric 11. A detailed explanation of the construction and the mode of operation of the drawing nozzle 8 can be found e.g. in EP 38 989 and EP 66 506. Responsible for the fraying and pulling effect in the drawing nozzle 8 is a pressure drop along the axis of the drawing nozzle, which is generated in a known manner by driving jets 12 (FIG. 2). Compressed air with a temperature of 50 ° -100 ° C and a static pressure of 10 bar is used as the blowing agent, which is supplied via the connections 13. Due to the pressure gradient, atmospheric air 14 is drawn in at a temperature of 20 ° C to 30 ° C at the drawing nozzle. Propellant and suction gas are drawn off below the storage chamber 9 and the conveyor belt 11 through the suction box 15.

Die Temperatur der Spinndüse 5 wird auf einem Wert im Bereich von 300°C bis 350°C konstant gehalten. Der Massendurchsatz pro Spinnbohrung beträgt 2,5 g/min.The temperature of the spinneret 5 is kept constant at a value in the range from 300 ° C to 350 ° C. The mass throughput per spinning bore is 2.5 g / min.

Die so erhaltenen Fasern 11 besitzen die in Figur 4 dar­gestellte Faserdurchmesserverteilung mit einem mittleren Faserdurchmesser von 4,1 µm und einem Variationskoeffi­zienten von 33 %.The fibers 11 obtained in this way have the fiber diameter distribution shown in FIG. 4 with an average fiber diameter of 4.1 μm and a coefficient of variation of 33%.

In dem Diagramm nach Figur 4 ist als Ordinate die Summe der Häufigkeiten aller vorkommenden Faserdurchmesser aufgetragen, die jeweils unterhalb eines auf der Abszisse dargestellten Fasergrenzdurchmessers liegen. Daraus ist zu erkennen, daß Fasern mit einem Durchmesser <2 µm und>8 µm praktisch nicht mehr vorkommen.In the diagram according to FIG. 4, the ordinate is the sum of the frequencies of all occurring fiber diameters, each of which is below a fiber limit diameter shown on the abscissa. From this it can be seen that fibers with a diameter of <2 µm and> 8 µm practically no longer exist.

Beispiel 2Example 2

Mit derselben Apparatur (Figur 1 und Figur 2), jedoch unter Verwendung von Stickstoff mit einer Temperatur von 150°C als Sauggas 14 wurden die Schmelzefäden unter sonst gleichen Bedingungen zu Feinstfasern mit einem Durchmesser von 1,5 µm bei einer Standardabweichung von 0,6 µm zerfasert und ausgezogen, die wiederum als Vlies 11 auf dem Transportband 10 abgeschieden wurden. Das so erzeugte Vlies zeichnet sich dadurch aus, daß es schrumpffrei ist.With the same apparatus (Figure 1 and Figure 2), but using nitrogen at a temperature of 150 ° C as the suction gas 14, the melt threads under otherwise identical conditions to fine fibers with a diameter of 1.5 microns with a standard deviation of 0.6 µm frayed and pulled out, which in turn were deposited as a fleece 11 on the conveyor belt 10. The fleece produced in this way is characterized by the fact that it is shrink-free.

Beispiel 3Example 3

Ebenfalls mit der gleichen Apparatur und unter den gleichen Bedingungen wie in Beispiel 1 wurde ein Faser­vlies erzeugt, das im Anschluß an die Faserablage einer thermischen Fixierung mit heißen Inertgas unterzogen wurde. Dabei wurde das Vlies zonenweise Temperaturen von 80°C bis 260°C ausgesetzt. Diese Maßnahmen wurden eben­falls angewandt, um einen Materialschrumpf zu verhin­dern.Also with the same apparatus and under the same conditions as in Example 1, a nonwoven fabric was produced, which was subjected to thermal fixation with hot inert gas after the fiber deposition. The fleece was exposed to temperatures of Exposed to 80 ° C to 260 ° C. These measures were also used to prevent material shrinkage.

Beispiel 4Example 4

Das bei den vorbeschriebenen Ausführungsbeispielen ange­wandte Ziehdüsenverfahren kann auch in der Weise modifi­ziert werden, daß der Schmelzestrom zunächst durch ein hohes statisches Druckgefälle zerfasert wird und an­schließend wiederum durch einen parallel strömenden Gas­strom ausgezogen wird (siehe Fig. 3). Zu diesem Zweck bildet die Spinndüse 5 zusammen mit der nachgeschalteten Ziehdüse 8 ein geschlossenes System. Die Schmelze 16 wird wie bei der Anordnung nach Figur 2 über ein Schmelzefilter dem Spinnippel 7 mit der Austrittsbohrung 6 zugeführt. Im Gegensatz zu der Vorrichtung nach Figur 2 ist jedoch zwischen der Unterkante der Spinndüse 5 und der Oberkante der Ziehdüse 8 rotationssymmetrisch um die Achse ein abgedichteter (18) geschlossener Druckraum 19 angeordnet. Dem allseitig geschlossenen Druckraum kann über die Bohrungen 20 Inertgas unter Druck zugeführt werden.The drawing nozzle method used in the above-described exemplary embodiments can also be modified in such a way that the melt flow is first defibrated by a high static pressure drop and then extracted again by a gas stream flowing in parallel (see FIG. 3). For this purpose, the spinneret 5 forms a closed system together with the downstream drawing nozzle 8. As in the arrangement according to FIG. 2, the melt 16 is fed to the spinning nipple 7 with the outlet bore 6 via a melt filter. In contrast to the device according to FIG. 2, however, a sealed (18) closed pressure chamber 19 is arranged between the lower edge of the spinneret 5 and the upper edge of the drawing nozzle 8 in a rotationally symmetrical manner about the axis. The pressure chamber, which is closed on all sides, can be supplied with inert gas 20 under pressure.

So wurde z.B. das inerte Druckgas mit einer Temperatur von 350°C und bei einem absoluten Druck von 10 bar in den Druckraum 19 eingebracht. Die Faserbildung 17 findet dann direkt in dem Druckgefälle und weiterhin aufgrund der aus dem Druckgefälle resultierenden Gasströmung (größter Druck im Druckraum 19) in der auf den Druckraum folgenden Lavaldüse 21 und dem nachgeschalteten Stoß­ diffusor 22 statt. Die Ablage der Fasern 17 zum Vlies 11 erfolgt in der gleichen Weise wie bei der Vorrichtung nach Figur 1 und 2. Mit den zuvor beschriebenen Betriebs­schriebenen Betriebsbedingungen wurden mit Hilfe dieser Variante Feinstfasern mit einem mittleren Faserdurch­messer von 0,6 µm und einer Standardabweichung von 0,4 µm hergestellt.For example, the inert compressed gas was introduced into the pressure chamber 19 at a temperature of 350 ° C. and at an absolute pressure of 10 bar. The fiber formation 17 then takes place directly in the pressure gradient and, furthermore, due to the gas flow resulting from the pressure gradient (greatest pressure in the pressure chamber 19) in the Laval nozzle 21 following the pressure chamber and the subsequent impact diffuser 22 instead. The laying of the fibers 17 to the fleece 11 takes place in the same way as in the device according to FIGS. 1 and 2. With the operating conditions described above, using this variant, very fine fibers with an average fiber diameter of 0.6 μm and a standard deviation of 0. 4 µm.

Eine weitere Verfahrensvariante zur Herstellung der er­findungsgemäßen PPS-Fasern besteht darin, daß die aus der Spinndüse austretenden Schmelzeströme in einem daran anschließenden offenen Raum (Freiraum) durch Heißluft mit hoher Geschwindigkeit im wesentlichen in Strömungs­richtung angeblasen werden. In diesem Fall kann also die auf die Spinndüse folgende Ziehdüse oder Lavaldüse ent­fallen. Das Verfahren ist unter dem Namen "Melt-Blown-­Verfahren" bekannt und wird z.B. in dem US-Patent 40 48 364 detailliert beschrieben. Es eignet sich insbe­sondere zur Verarbeitung von niedrigviskosen Schmelzen.A further process variant for the production of the PPS fibers according to the invention consists in that the melt streams emerging from the spinneret are blown at high speed essentially in the flow direction in a subsequent open space (free space) by hot air. In this case, the drawing nozzle or Laval nozzle following the spinneret can be omitted. The process is known under the name "melt blown process" and is e.g. in detail in U.S. Patent 4,048,364. It is particularly suitable for processing low-viscosity melts.

Als Ausgangsmaterial wurde in allen Fällen Polyphenylen­sulfid in Form von Granulat verwendet. Besonders geeig­net sind die zur Gruppe der Polyphenylensulfide gehö­renden Polyarylensulfide, deren Herstellung und Eigen­schaften in EP 171 021 näher beschrieben sind.In all cases, polyphenylene sulfide in the form of granules was used as the starting material. Particularly suitable are the polyarylene sulfides belonging to the group of polyphenylene sulfides, the production and properties of which are described in more detail in EP 171 021.

Claims (8)

1. Fasern, Faservliese oder Faserhaufwerke aus Poly­phenylsulfid (PPS), oder Mischungen aus PPS mit anderen Polymeren, die durch Weiterverarbeitung der aus einer Spinndüse mit mindestens einer Bohrung mit einem Durchmesser von 0,05 mm bis 2 mm austre­tenden Polymer-Schmelzeströme erhalten werden, da­durch gekennzeichnet, daß Fasern mit einem mittle­ren Faserdurchmesser von <6 µm, vorzugsweise 0,2 µm bis 6 µm, dadurch erzeugt werden, daß die Schmelze­ströme durch ein im wesentlichen parallel dazu strömendes, längs einer Zone von 2 mm bis 100 mm, vorzugsweise 2 mm bis 50 mm, und in einem lateralen Abstand von 2 mm bis 30 mm von den Austrittsbohrun­gen Schall- oder Überschallgeschwindigkeit errei­chendes gasförmiges Medium ausgezogen und unter die Schmelzetemperatur abgekühlt werden, wobei durch gleichzeitige Deformation und Abkühlung amorphe Fein-bzw. Feinstfasern endlicher Länge entstehen, die zu einem Faservlies oder Faserhaufwerk abgelegt werden.1. Fibers, non-woven fabrics or fiber piles made of polyphenyl sulfide (PPS), or mixtures of PPS with other polymers, which are obtained by further processing the polymer melt streams emerging from a spinneret with at least one bore with a diameter of 0.05 mm to 2 mm, characterized in that fibers with an average fiber diameter of <6 µm, preferably 0.2 µm to 6 µm, are produced in that the melt flows through a flow essentially parallel to it, along a zone of 2 mm to 100 mm, preferably 2 mm to 50 mm, and at a lateral distance of 2 mm to 30 mm from the outlet bores sound or supersonic velocity reaching gaseous medium and cooled to below the melt temperature, amorphous fine or respectively by simultaneous deformation and cooling. Very fine fibers of finite length are created, which are laid down to form a nonwoven or fiber pile. 2. Fasern nach Anspruch 1, dadurch gekennzeichnet, daß die Schmelzeströme zusätzlich durch Einwirkung eines auf die Schmelzeströme im wesentlichen längs einer Zone von 1 mm bis 30 mm, vorzugsweise 2 mm bis 10 mm, im Anschluß an die Austrittsbohrungen einwirkendes statisches Druckgefälle ausgezogen werden.2. Fibers according to claim 1, characterized in that the melt streams are additionally pulled out by the action of a on the melt streams essentially along a zone of 1 mm to 30 mm, preferably 2 mm to 10 mm, following the outlet bores acting static pressure drop. 3. Fasern nach Anspruch 1 bis 2, dadurch gekennzeich­net, daß die Fasern aus Schmelzen mit einer Spinn­viskosität von 2 Pas bis 250 Pas, vorzugsweise 80 Pas bis 150 Pas, und bei einer Schmelzetemperatur von TS = 310°C erzeugt werden.3. Fibers according to claim 1 to 2, characterized in that the fibers are produced from melts with a spinning viscosity of 2 Pas to 250 Pas, preferably 80 Pas to 150 Pas, and at a melt temperature of T S = 310 ° C. 4. Fasern nach Anspruch 1 bis 3, dadurch gekennzeich­net, daß die Faserdurchmesserverteilung einer engen Gaußschen Verteilung mit einem Variationskoeffi­zient <50 %, vorzugsweise zwischen 10 % und 35 %, gehorcht und die Fasern ohne thermische Fixierung eine Festigkeit von 0,4 bis 1,1 GPa und eine Deh­nung von 20 % bis 80% und nach thermischer Fixie­rung unter Spannung eine Festigkeit von 0,6 GPa bis 1,1 GPa und eine Dehnung von 10 % bis 30 % aufwei­sen.4. Fibers according to claim 1 to 3, characterized in that the fiber diameter distribution of a narrow Gaussian distribution with a coefficient of variation <50%, preferably between 10% and 35%, and the fibers without thermal fixation have a strength of 0.4 to 1, 1 GPa and an elongation of 20% to 80% and, after thermal fixing under tension, a strength of 0.6 GPa to 1.1 GPa and an elongation of 10% to 30%. 5. Verfahren zur Herstellung von Polymer-Fasern, da­durch gekennzeichnet, daß aus Spinnbohrungen aus­tretende Polymer-Schmelzeströme auf der Basis von Polyphenylensulfid (PPS) unter der Einwirkung eines parallel dazu strömenden Inertgases mit einer Tem­peratur von 20° bis 280°C, vorzugsweise 80°C bis 200°C, zu endlich langen Feinfasern ausgezogen und unter die Schmelzetemperatur abgekühlt werden.5. A process for the production of polymer fibers, characterized in that polymer melt streams emerging from spinning bores based on polyphenylene sulfide (PPS) under the action of an inert gas flowing parallel thereto at a temperature of 20 ° to 280 ° C, preferably 80 ° C to 200 ° C, drawn into finely long fine fibers and cooled below the melt temperature. 6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, daß durch Verwendung heißer Inertgase eine thermi­sche Fixierung der Faser direkt im Anschluß an den Faserbildungsprozeß erfolgt.6. The method according to claim 5, characterized in that a thermal fixation of the fiber takes place directly after the fiber formation process by using hot inert gases. 7. Verfahren nach Anspruch 5, dadurch gekennzeichnet, daß die Fasern einer thermischen Fixierung mittels Kalander oder durch Inertgase bei einer Temperatur von 80°C bis 260°C vorzugsweise in mehreren Stufen unterzogen werden.7. The method according to claim 5, characterized in that the fibers are subjected to thermal fixation by means of calenders or by inert gases at a temperature of 80 ° C to 260 ° C, preferably in several stages. 8. Verfahren nach Ansprüchen 1 bis 7, dadurch gekenn­zeichnet, daß als Ausgangsmaterial für die Polymer­schmelze Mischungen von PPS und Polybutylentere­phthalat mit einem Mischungsverhältnis von 2:1 bis 10:1, vorzugsweise 4:1 bis 8:1, verwendet werden.8. Process according to claims 1 to 7, characterized in that mixtures of PPS and polybutylene terephthalate with a mixing ratio of 2: 1 to 10: 1, preferably 4: 1 to 8: 1, are used as the starting material for the polymer melt.
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