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
  • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
  • D01F2/02—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from solutions of cellulose in acids, bases or salts
• • 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
  • D01D1/00—Treatment of filament-forming or like material
  • D01D1/02—Preparation of spinning solutions
• • 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
  • D01D10/00—Physical treatment of artificial filaments or the like during manufacture, i.e. during a continuous production process before the filaments have been collected
  • D01D10/06—Washing or drying
• • 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
  • D01D13/00—Complete machines for producing artificial threads
  • D01D13/02—Elements of machines in combination
• • 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
  • D01D5/06—Wet spinning methods
• • 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
  • D01D5/26—Formation of staple fibres
• • 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
  • D01F11/00—Chemical after-treatment of artificial filaments or the like during manufacture
  • D01F11/02—Chemical after-treatment of artificial filaments or the like during manufacture of cellulose, cellulose derivatives, or proteins
• • 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
  • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
  • D04H1/06—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres by treatment to produce shrinking, swelling, crimping or curling of fibres
  • D04H1/067—Regenerated cellulose series
• • 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
  • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
  • D04H1/28—Regenerated cellulose series
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
  • D21H13/02—Synthetic cellulose fibres
  • D21H13/08—Synthetic cellulose fibres from regenerated cellulose
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
  • D10B2201/20—Cellulose-derived artificial fibres
  • D10B2201/22—Cellulose-derived artificial fibres made from cellulose solutions

Definitions

• the current disclosure relates to innovations in the field of the production, use and application of man-made cellulosic fibers. Particularly the current disclosure relates to processes for the production of regenerated cellulosic fibers which are produced according to a cold-alkali process, the thus produced fibers and their use.
• Man-made cellulosic fibers are manufactured fibers that are based on cellulosic matter as a source material.
• cellulose denotes an organic compound derived from plant cell walls or synthetically produced.
• Cellulose is a polysaccharide and is unbranched.
• cellulose comprises several hundred to ten thousand b-D-glucose molecules ⁇ -1,4-glycosidic bound) or cellobiose units, respectively.
• the cellulose molecules that are used by plants to produce cellulose fibers are also used in technical processes to produce regenerated cellulose.
• regenerable cellulose denotes a class of materials manufactured by the conversion of natural or recycled cellulose to a soluble cellulosic derivative or a directly dissolved cellulose solution and subsequent regeneration, forming shaped bodies, such as fibers (e.g., rayon), films or foils (e.g., cellophane) or bulk solids (e.g. beads, powders or pellets).
• fibers e.g., rayon
• films or foils e.g., cellophane
• bulk solids e.g. beads, powders or pellets.
• fibers denotes continuous filaments as well as cut staple fibers of any desired length.
• Cellulosic fibers can also be in the form of a woven, knitted or non-woven fabric comprising the cellulosic fibers.
• Woven fabrics comprise textile planar fabrics made from at least two crossed thread systems, which can be referred to as warp- and weft-yarns.
• the yarn in knitted fabrics follows a meandering path (a course), forming symmetric loops (also called bights) symmetrically above and below the mean path of the yarn.
• the term “non-woven fabric” denotes fabrics that are neither woven nor knitted.
• Non- woven fabrics can be in the form of a fabric comprising randomly oriented fibers and/or cut yarns of finite length.
• Non-woven fabrics can also comprise endless yarns, e.g. produced by a melt-blown-process.
• viscose fibers As viscose fibers, regenerated cellulosic fibers are denoted, which are manufactured by means of a wet spinning method which is called viscose-method.
• the starting raw material of the viscose-method is cellulose which is usually provided on the basis of wood. From this starting raw material a highly pure cellulose in form of chemical pulp is obtained. Additionally or as an alternative other cellulosic materials, such as bamboo, cotton linters, recycled cellulosic materials, reed, etc., or mixtures of such materials can be used as a starting raw material.
• the pulp In subsequent process stages, the pulp is first treated with caustic soda (NaOH), whereby alkali cellulose is formed.
• CaOH caustic soda
• cellulose- xanthogenate is formed.
• the viscose-spinning solution is generated which is pumped through holes of shower-like spinning nozzles into a coagulation bath (also referred to as spin bath).
• a coagulation bath also referred to as spin bath.
• one viscose-filament per spinning nozzle hole is generated by coagulation.
• an acidic coagulation bath is used to coagulate the spinning solution.
• the thus generated viscose-filaments are subsequently post processed.
• the post processing usually comprises several washing- and stretching steps and the filaments are cut to viscose-staple fibers.
• Licell denotes a regenerated fiber type comprising cellulose, which is manufactured according to a direct solvent method.
• the cellulose for the lyocell-method is extracted from the raw material containing the cellulose.
• the thus obtained pulp may subsequently be dissolved in a suitable solvent under dehydration without chemical modification.
• N- methylmorpholine-N-oxide NMMO
• ionic liquids can also be used for the process.
• the solution is then filtered and, for the production of fibers, subsequently extruded through spinning nozzles into an air gap where they are drawn and coagulated by means of a moist airstream and then are fed into a coagulation bath containing an aqueous NMMO-solution. Subsequently the fibers can be further processed, e.g. washed, bleached, finished, crimped, cut to staple fibers, etc.
• Another well-known process for the manufacturing of regenerated cellulose fibers is the carbamate-method, which is similar to the viscose-process but uses urea instead of carbon disulfide.
• Still another process, which is called modal-process is a modified viscose-process for the production of higher quality fibers. For these processes, also an acidic coagulation bath is used.
• processes for manufacturing of cellulosic products can use an alkaline spin bath comprising a salt.
• cellulose is dissolved in an aqueous alkaline medium at a controlled temperature.
• Such processes are herein generally denoted as “cold-alkali process”.
• WO2018/169479 discloses an example of a fiber produced by a cold-alkali process.
• the method comprises: providing a spinning dope comprising a solution of cellulose and an additive in an alkaline solvent, in which solvent cellulose is present at a concentration of from about 5 to 12 percent per weight by weight and the additive is present in the range of from 0.1 - 10 percent per weight by weight calculated on the cellulose; contacting the cellulose spinning dope with an aqueous coagulation bath fluid having a pH value above 7 and comprising a salt; forming a regenerated cellulosic fiber composition; and stretching and washing the fiber composition in one or more washing and stretching baths.
• EP3231901A1 discloses a similar process, wherein a spin dope is prepared by dissolving cellulose in an aqueous NaOH solution.
• the spin bath comprises a coagulation liquid comprising an aqueous sodium salt solution.
• EP3231899A1 discloses a method for preparing a spin dope by direct dissolution of cellulose in cold alkali.
• WO2020171767A1 discloses a process for forming a fiber tow involving a wet spinning procedure comprising the steps of: dissolving cellulose pulp in an alkaline aqueous solvent to form a cellulose spin dope composition, spinning the cellulose spin dope composition in a coagulation bath having a pH of more than 7.0, preferably a pH of at least 10, to produce a fiber tow, and passing the produced fiber tow through a sequence of consecutive stretching and washing steps in which the formed fiber tow is washed with a washing liquid by a counter-current flow washing procedure.
• Especially fibers that are produced according to the cold-alkali process issue numerous challenges to the post-processing of the fiber. Subsequent production steps, such as carding, yarn spinning, textile production or fleece production, require staple fibers having, for example, a sufficiently high tenacity, low brittleness and an appropriate crimp.
• Crimping the fibers is generally done by specially profiled rollers that press the fiber tow into a wavy pattern before they are cut to staple fibers in a cutter.
• the fiber tow has to be crimped as long as it is still in a sufficiently formable state.
• the resulting staple fibers have a characteristic appearance, wherein bundles of fibers can be identified that are arranged in an exactly parallel wavy pattern.
• the crimp of all fibers show the same length and curvature which gives them a regular appearance.
• natural crimp designates a crimp pattern of fibers that comprises waves of different and randomly distributed curvature and length. Such fibers resemble more closely to crimp of some natural fibers, such as cotton of wool.
• the present disclosure describes methods and apparatuses for producing regenerated fibers and specifically for the post-processing of a fiber tow of regenerated cellulosic fibers that allow for the production of naturally crimped fibers that are produced according to a cold-alkali process.
• the present disclosure relates to a method for producing regenerated cellulosic fibers comprising extruding a spinning solution into a coagulation bath which contains a salt and preferably an alkali to produce a fiber tow, the spinning solution comprising cellulose dissolved in an aqueous solvent comprising NaOH and ZnO, the coagulation bath having a pH-value of at least seven, wherein the method comprises at least the following steps: cutting the fiber tow in an undried state into cut fibers, suspending the cut fibers and collecting them in form of a non-woven fiber layer, pressing the non-woven fiber layer, thereby imposing a natural crimp on the fibers.
• the method allows for the production of naturally crimped fibers having improved post-processing properties.
• the person skilled in the art and having knowledge of the teachings disclosed herein is able to choose a suitable salt for use in the coagulation bath.
• the salt facilitates a coagulation of the spinning solution and preferably can be present in the coagulation bath in a ratio ranging from 10 percent per weight to 30 percent per weight.
• the salt is a sodium salt, e.g. sodium carbonate or sodium sulfate.
• suitable salts can be chosen by taking into account the Hofmeister series (also known as the lyotropic series), which classifies ions in order of their precipitation capacities.
• the salt should, for one thing, allow for a quick coagulation and secondly, it should facilitate recovery and recycling of the compounds.
• Alternative, but less preferred coagulation sodium salts include sodium salts wherein the counter ion is a carboxylate (e.g. formate, acetate, propionate, butyrate or benzoate), an aliphatic or aromatic sulfonate (e.g.
• the anionic counter ion has a dense electric charge, placing it in the beginning of the Hofmeister series.
• Anionic counter ions having a dense electric charge are characterized as strongly "salting out" proteins, due to their ability to increase surface tension and organize water molecules in solvation shells around them.
• the coagulation sodium salt is preferably a sodium salt precipitating as a hydrate.
• the molar ratio of water to sodium salt in the precipitated hydrate is at least 4: 1.
• the method can comprise a step wherein the fibers in the fiber tow are stretched to essentially their final cellulose specific diameter and oriented to essentially their final state before being cut to staple fibers in an undried state. This allows for the production of fibers with good performance in terms of tensile strengths and elongation.
• the term “stretched to essentially the final cellulose specific diameter”, as it is used herein, is to be interpreted to that effect that downstream of this stretching step no further stretching steps are preformed on the fiber tow, i.e. the diameter of the fibers is held essentially constant until the fibers are either cut (after which a small amount of relaxation is unavoidable and sometimes even intended) or dried (where the diameter of the fibers as it would be actually measured is reduced due to the loss of liquid, generally without any change of the stretch of the fibers).
• cellulose specific diameter denotes a diameter in a virtually washed and dried state, i.e. only comprising the dry cellulose.
• the fiber titer which is defined as the weight of the cellulosic contents of the fiber per unit of length.
• the diameter corresponds to the diameter of the circular cross-section.
• the diameter corresponds to the diameter of the largest circle that can be inscribed into the cross-section of the fiber (across the main axes).
• the diameter of a fiber having an elliptic diameter would correspond to the lengths of the minor axis of the ellipse.
• the term “undried”, as it is used herein, defines a state, where the wet fiber has only been dewatered with mechanical means, i.e. by squeezing, and has not undergone any drying step. More specifically, the term designates a never-dried fiber, i.e. a fiber that has not undergone any drying step after extrusion.
• the fiber tow is routed into at least one conditioning bath, the conditioning bath comprising from 10 percent per weight to 30 percent per weight a salt that facilitates a further coagulation of the spinning solution, the conditioning bath preferably being fluidly separated from a downstream washing line, wherein the fibers in the fiber tow are stretched to essentially their final cellulose specific diameter and oriented to essentially their final state in the at least one conditioning bath.
• the method allows for a cost-effective fiber production and reduces the complexity of threading the fiber tow at the production startup.
• the term “fluidly separated”, as it is used herein, denotes systems that are either associated to completely separated circulation systems, or that are connected via an installation that significantly changes the properties of the liquid, e.g. by adding substances to and/or removing substances from the liquid or by concentrating or diluting the liquid.
• the salt in the conditioning bath can preferably be identical to the salt that is used in the coagulation bath, or it can be chosen according to the same requirements as the salt in the coagulation bath that are outlined above.
• the coagulation bath and the conditioning bath are fluidly connected, wherein the temperature of the coagulation bath and the temperature of the conditioning bath can preferably be independently set, adjusted and/or maintained. This facilitates the setup of optimized process conditions that allow for a complete and advantageous orientation and a strong stretching of the fibers in the conditioning bath.
• fluidly connected denotes units (e.g. a bath, such as the coagulation bath or the conditioning bath, or a washing unit) that are associated to the same circulation system, without having interposed between them an installation that significantly changes the properties of the liquid, e.g. by adding substances to and/or removing substances from the liquid or by concentrating or diluting the liquid.
• a bath such as the coagulation bath or the conditioning bath, or a washing unit
• one unit can be serially connected to another unit and being traversed by a liquid stream, e.g. in a countercurrent-arrangement or in a concurrent-arrangement.
• the fluidly connected units could be independently fed from the same reservoir.
• conditioning baths instead of only one conditioning bath, also a series of two or more conditioning baths could be applied. This would allow an individual adjustment of the temperature of the coagulation liquid and a stepwise stretching of the fibers at different temperatures. On one hand, this would increase the costs and the complexity of the production process, on the other hand it could be possible to improve fiber properties.
• the fiber tow is routed through a washing line, the washing line comprising at least one washing step, wherein the washing line is preferable arranged downstream of the at least one conditioning bath, and wherein the tension of the fiber tow and the cellulose specific diameter of the fibers are preferably kept essentially constant in the washing line.
• the method described herein can further be improved by any technically feasible combination of one or more of the following steps: Washing the fiber tow or the non-woven fiber layer preferably with water. Washing the already cut fibers in form of a non-woven fiber layer can be realized in a more economic way that it is possible with the uncut fiber tow.
• Neutralizing the fiber tow or the non-woven fiber layer with an acidic liquid wherein the acidic liquid may preferably be selected from diluted acetic acid, lactic acid, sulphuric acid or the like. Alkaline residues can so be neutralized.
• a second washing step can be done after the neutralizing step to wash out the salts that formed during the neutralizing step.
• finishing agent particularly a soft finish
• the (soft) finishing improves the spinnability of the fibers and the quality of the so produced products.
• Squeezing the fiber tow or the non-woven fiber layer before and/or after any other processing step can, for example, be easily done by running the non-woven fiber layer of cut fibers through pressing rollers. Especially at the beginning of the post-processing of the non-woven fiber layer the additional pressing can change and further improve the extent and quality of the crimp.
• the post-processing further can comprise at least one step of opening the non-woven fiber layer to loosen up and/or at least partially separate the fibers.
• the opening can improve downstream post-processing steps, such as drying and baling, and facilitates the opening of the baled fibers.
• the opening allows to provide a fiber layer with a higher density in the upstream post-processing steps, which can be then be implemented in a more economic way.
• the present disclosure relates to a processing facility for producing regenerated cellulosic fibers
• a processing facility for producing regenerated cellulosic fibers comprising a spinneret for extruding a spinning solution into a coagulation bath which contains a salt and preferably an alkali to produce a fiber tow, the spinning solution comprising cellulose dissolved in an aqueous solvent comprising NaOH and ZnO, the coagulation bath having a pH- value of at least seven
• the processing facility comprises a cutter to cut the fiber tow in an undried state into cut fibers, a fleece-forming device for suspending the cut fibers and collecting them in form of a non-woven fiber layer, and at least on pressing device for pressing the non-woven fiber layer, thereby imposing a natural crimp on the fibers.
• the processing facility allows for the industrial implementation and scale-up of the methods disclosed herein. A crimping facility in the fiber-tow line is not needed.
• the facility further comprises at least one stretching device for stretching the fibers in the fiber tow to essentially their final cellulose specific diameter and orienting the cellulose in the fibers to essentially their final state.
• the facility further can comprise at least one conditioning bath downstream of the coagulation bath, the conditioning bath comprising from 10 percent per weight to 30 percent per weight a salt that facilitates a further coagulation of the spinning solution, the conditioning bath preferably being fluidly separated from a downstream washing line, and at least one stretching device for stretching the fibers in the fiber tow to essentially their final cellulose specific diameter and orienting the cellulose in the fibers to essentially their final state within the at least one conditioning bath.
• the conditioning bath comprising from 10 percent per weight to 30 percent per weight a salt that facilitates a further coagulation of the spinning solution
• the conditioning bath preferably being fluidly separated from a downstream washing line
• at least one stretching device for stretching the fibers in the fiber tow to essentially their final cellulose specific diameter and orienting the cellulose in the fibers to essentially their final state within the at least one conditioning bath.
• the coagulation bath and the conditioning bath are fluidly connected, wherein the temperature of the coagulation bath and the temperature of the conditioning bath can preferably be independently set, adjusted and/or maintained.
• the coagulation speed can be optimized to provide sufficiently strong and extensible fibers.
• the fiber tow is routed through a washing line, the washing line comprising at least one washing step, wherein the washing line is preferable arranged downstream of the at least one conditioning bath, and wherein the tension of the fiber tow and the cellulose specific diameter of the fibers are preferably kept essentially constant in the washing line. Washing the fiber tow in a tensioned state (and preferably without stretching them any further) can improve fiber properties.
• the processing facility may further comprise one or more treatment facilities, which are independently selected from a list comprising: one or more washing devices for washing the fiber tow or the non-woven fiber layer, one or more further pressing devices for squeezing the fiber tow or the non- woven fiber layer, a neutralizer for neutralizing the cut or uncut fibers with an acidic liquid, a bleaching facility for bleaching the cut or uncut fibers, a crosslinking facility for the application of a crosslinking agent on the cut or uncut fibers, a finishing facility for applying a finishing agent, particularly a soft finish, to the cut or uncut fibers, an opener for opening the non-woven fiber layer to loosen up and/or at least partially separate the cut fibers, a dryer, preferably a drum dryer or a conveyor dryer, to dry fibers.
• one or more washing devices for washing the fiber tow or the non-woven fiber layer
• one or more further pressing devices for squeezing the fiber tow or the non- woven fiber layer
• a neutralizer for
• the present disclosure relates to regenerated cellulosic fibers produced in a processing facility as described herein and/or produced by a method as described herein.
• the fibers can meet enhanced quality standards, both in view of requirements for further processing steps as well as in terms of properties of intermediate- and end products comprising the fiber.
• the present disclosure relates to a product, particularly a consumer product or an intermediate product, comprising the regenerated cellulosic fibers as disclosed herein.
• the product can be selected from a list comprising yarns, fabrics, textiles, home textiles, garments, nonwovens, hygiene products, upholstery, technical applications, such as filter material, paper.
• Fig. 1 is a schematic and exemplified representation of a fiber production process according to the present disclosure focusing on the spinning dope preparation and
• Fig. 2 is a schematic and exemplified representation of processing facility according to the present disclosure focusing on the post-processing of the spun fibers.
• Fig. 1 shows a flowchart representing an exemplary fiber production process according to the present disclosure.
• the diagram is a simplified representation and shows the process in a schematized manner.
• a broad range of possible cellulosic raw materials can be used.
• the intrinsic viscosity and the degree of polymerization of the cellulose used as a raw material is lower than it is common for the viscose- or lyocell-process.
• dissolving pulp kraft or sulphite
• an intrinsic viscosity measured in Cuen, according to SCAN-CM 15:99
• an intrinsic viscosity measured in Cuen, according to SCAN-CM 15:99
• degree of polymerization DP of 500 to 1900 preferably between about 250 and about 400 mL/g (DP or 600 to 950)
• recycling pulp or cotton linters preferably having the same DP as stated above
• the recycling pulp can, for example, be derived from waste paper, recycled viscose textile material, recycled modal textile material, recycled lyocell textile material an/or recycled cotton fiber textile material. Blends of pulps of different origin, such as blends of virgin wood pulp with recycling pulp, are possible and may be even desirable.
• a staple of dissolving pulp 1 is exemplarily depicted as the raw material
• the cellulosic raw material can be subjected to a pretreatment, wherein the degree of polymerization is adjusted to a desired DP to adjust the viscosity of the spinning dope to a value that allows for filtering and spinning.
• the pretreatment can comprise subjecting the raw material to an acidic pulp treatment, wherein the DP-value is mainly influenced by the duration of the pretreatment and the concentration of the acid. In other cases the pretreatment can be omitted, if the DP-value is already at the desired value.
• pulp derived from cellulosic regenerate fibers may have a DP that allows for a direct dissolution without a pretreatment.
• an acidic pulp treatment with 1-10 percent per weight sulfuric acid at 50°C to 95°C for a duration from 5min to 2h can be used as a pretreatment.
• the person skilled in the art, who is aware of the teachings of this disclosure is able to find suitable parameters and optimize them without undue burden.
• the pretreatment further comprises washing the cellulosic material with water and pressing to reduce moisture content, e.g. to about 50 percent per weight of the cellulosic material.
• a source for a pretreatment chemical 2 e.g. sulfuric acid
• a pretreatment vessel 3 After the pretreatment in pretreatment vessel 3 the cellulosic material can be squeezed and washed to reduce the amount of acid that is transported to the next step.
• the wet and pretreated pulp is first cooled to about 0°C (while freezing of the pulp should be avoided), and an aqueous solvent comprising NaOH and ZnO is prepared.
• the solvent is adjusted to provide a spinning solution comprising 5 to 10 percent per weight NaOH and 0.8 to 3 percent per weight ZnO.
• the solvent is cooled down to a process temperature, which preferably lies between -5°C and -10°C.
• the pulp and the solvent are blended to dissolve the cellulose in the solvent.
• the preparation of the spinning dope comprises a mixing step followed by a homogenization step.
• the blend is mixed with a high shear stress, which can be done in a high-shear mixer.
• This high shear stress mixing is preferably only performed for a rather short period of time, for example the mixing can be done for 1 - 2 minutes.
• the blend is agitated with a lower shear intensity.
• the homogenization step can last longer than the mixing step, for example about 5 minutes.
• the temperature of the mixture is controlled, especially cooled.
• the temperature is kept below 0°C.
• the process temperature should never exceed 5°C, as the solution could then thicken and be irrecoverably lost.
• the so prepared spinning solution is then filtered and de-aerated.
• the spinning dope can be filtrated at least twice via a KK filter (Kolben-Korb-Filter,
• the spinning solution is exposed to reduced pressure. This step is per-se known from the viscose process. Other techniques for filtering and de-aerating the dope that can be used are known to the person skilled in the art.
• the prepared spinning dope should be free of voids, have a homogenous consistency and a proper viscosity that allows for an extrusion in the spinneret used in the following extrusion step.
• the ballfall-viscosity of the spinning dope should be in the range of about 30 to 200 s.
• the ballfall-viscosity can be measured according to DIN 53015-2019.
• the viscosity of the spinning dope can be adjusted by several different means.
• the viscosity can be adjusted by altering the DP-value of the cellulose, by changing the composition of the solvent and/or the concentration of the cellulose in the spin dope.
• the concentration of the cellulose can be in the range of about 4 percent per weight to about 12 percent per weight, particularly in the range of about 5 percent per weight to about 8 percent per weight preferably about 6 percent to about 7 percent per weight.
• Fig. 1 a chemical repository 4 for the storage of the ingredients of the solvent, a solvent cooling device 5 for the cooling of at least parts of the solvent, a pulp cooling device 6, a mixing vessel 7 and a de-aerating filter 8 are exemplarily depicted.
• the mixing vessel 7 is provided with a cooling jacket 9.
• the spinning dope can be extruded through a nozzle directly into a coagulation bath.
• the dope can be homogenized via a static mixer to incorporate additives.
• the dope can preferably be tempered to spinning temperature, for example to a temperature in the range of from 5°C to 30°C.
• a spinneret comprising, for example, up to 150 cups with a diameter of 12.5 to 16 mm, comprising up to 3000 holes with a diameter of about 40 to 75 micrometer, which corresponds to dimensions as they are known per se and commonly used in connection with the viscose spinning process.
• a spinneret comprising holes with a diameter of about 80-120 pm, preferably between 90 and 110 pm.
• one spinneret could comprise up to 150 cups with a diameter of 12,5 to 16 mm, comprising about 600 to 1400 holes with a diameter of about 80-120 pm, preferably between 90 and 110 pm.
• the relatively thick diameter of the spinning holes causes different course of coagulation, i.e. that the freshly extruded fibers first only coagulate at the outer surface, while the middle of the fiber stays in a liquid state for a longer time. This allows for a higher stretching and the stretching conditions can be uphold in a more stable way.
• the coagulation bath comprises an alkali, preferably NaOH, and a salt, preferably sodium carbonate, Na2CC>3, or sodium sulfate, Na2SC>4.
• the coagulation bath can comprise from 10 percent per weight to 30 percent per weight Na2CC>3 or Na2SC>4 and from 0 to 3 percent per weight NaOH, preferably from 0.1 to 3% and still more preferred from 0.2 to 0.7 percent per weight NaOH.
• the coagulation bath can comprise about 22 percent per weight Na2C03 and about 0.5 percent per weight NaOH.
• the temperature of the coagulation bath can, for example, be adjusted to between 10°C and 30°C, and preferably be tempered at about 20°C.
• the optimal distance, that the freshly extruded fiber travels through the coagulation bath depends, inter alia, on the extrusion speed, the pull-off speed, the composition and consistency of the spinning dope, the composition of the coagulation bath and the temperature. Without being restricted to these values, under most parameter conditions the optimal coagulation bath distance may be found within a range from about 10 cm to about 100 cm. Preferred values for the coagulation bath distance range from about 15 cm to about 60 cm.
• the fiber tow is drawn out of the coagulation bath to a transporting section, which can comprise several godets and/or pulleys that transport the fiber tow through a series of post-processing stages.
• the pull-off force that is exerted on the freshly extruded fibers can be regulated by the extrusion speed and the speed of the first transporting unit (or godet), which preferably can be positioned outside of the coagulation bath. Due to the pull-off force, which is exerted on the freshly extruded fibers by the first transporting unit, the fibers get stretched already inside the coagulation bath. Further stretching steps can be during the following post processing of the fibers.
• a coagulation bath 10 comprising a coagulation liquid 11, a spinneret 12 and a first godet 13 are exemplarily depicted.
• the spinneret 12 extrudes a number of fibers 14 (corresponding to the number of holes of the spinneret 12) into the coagulation liquid 11.
• the freshly extruded fibers 14 are gathered together into a fiber tow 15 by the first godet 13.
• the amount of stretching that is done directly after extrusion within the coagulation bath 10 can be set.
• an inclined angle of the spinneret 12 (and the freshly extruded fibers 14) is shown in Fig. 1, the skilled practitioner, who is aware of the current teaching, is able to apply other spinning configurations that are per se known in the field, e.g. from viscose production.
• post-processing encompasses all processing steps that are performed on the extruded fibers after they have been withdrawn from the coagulation bath. Post-processing steps can be applied to the fiber tow while it is transported on the transporting unit. Additionally, the fiber tow can be cut in a cutting apparatus and further post-processing steps can be performed on the cut fibers.
• Post-processing of the fibers can comprise, but are not restricted to, any combination of one or more of the following steps:
• a counter current flow washing can be implemented in the post processing, wherein the fibers in the fiber tow are being incrementally stretched during and/or in-between the several washing steps until they have reached their final extension.
• the fiber tow can be led into a conditioning bath comprising from 10 percent per weight to 30 percent per weight a salt that facilitates a further coagulation of the spinning solution, the conditioning bath preferably being fluidly separated from any downstream washing facilities, and stretched to essentially the final cellulose specific diameter of the fibers and oriented to essentially their final state within the conditioning bath.
• the conditioning bath can comprise a coagulation liquid that is similar or identical to the coagulation bath liquid.
• the coagulation speed in the conditioning bath can be adjusted by the temperature of the liquid therein, which preferably can be controlled independently from the coagulation bath.
• the fiber tow can be washed in a downstream washing line, where no additional stretching is applied to the fiber.
• Fig. 2 is a schematic block-diagram showing an exemplary configuration of a post processing facility for treating a fiber-tow which is produced according to the current disclosure, e.g. by the facility depicted in Fig. 1.
• Fibers 14 are extruded by a spinneret 12 into a coagulation liquid 11 within a coagulation bath 10 and gathered together into a fiber tow 15 by the first godet 13 (similar to Fig. 1). From the first godet 13 the fiber tow is directed to a second godet 18. Between the first godet 13 an the second godet 18 the fiber tow 15 is diverted via a guide 16, e.g. a roller, bar or the like, and submerged into a conditioning bath 17 containing a coagulation liquid 11’.
• the coagulation liquid can be identical or similar to the coagulation liquid 11 in the coagulation bath 10.
• the coagulation liquid 11 in the coagulation bath 10 and the coagulation liquid 1T in the conditioning bath 17 are circulated in a common fluid cycle.
• the temperature of the coagulation liquid 1T in the conditioning bath 17 can be controlled independently from the temperature of the coagulation liquid 11 in the coagulation bath 10. Generally a higher temperature is preferred for the coagulation liquid 1 T in the conditioning bath 17.
• the temperature of the coagulation liquid 11 in the coagulation bath 10 can be adjusted to a value between about 10 °C and about 20°C and the temperature of the coagulation liquid 1T in the conditioning bath 17 can be adjusted to a value between about 20 °C and about 40 °C.
• the fibers in the fiber tow are stretched to essentially their final cellulose specific diameter and oriented to essentially their final state.
• Fig. 2 only one conditioning bath is shown. Nonetheless it would be possible to install more than one conditioning bath, for example two successive conditioning baths or a series of consecutive conditioning baths.
• the conditioning baths share the same fluid circuit with the coagulation bath and have an essentially identical or at least similar content of salt and/or alkali.
• the temperatures of the conditioning baths can either be the same or controlled independently, as the case may be.
• the fibers can, for example, be stretched in a cascading style, i.e. consecutive conditioning baths have an increasing stretching rate.
• the fibers could also be stretched to essentially their final state in an upstream conditioning bath (or several upstream conditioning baths) and than be further coagulated and “fixated” within one (ore more) downstream conditioning bath(s) with constant speed and stretch.
• the person skilled in the art and having knowledge of the teachings disclosed herein is able to optimize the number of conditioning baths, their temperatures and extension rated by routine tests and experiments without deviating from the scope of the current disclosure.
• the fiber parameters such as tensile strength, elongation, crystallinity etc., can so be optimized in a methodical manner.
• the fiber tow 15 is directed to a washing line 19 which can comprise several washing steps which are exemplarily depicted in Fig. 2 as washing steps 20 and 20’.
• the washing line 19 can also comprise only one washing step 20 or any number of washing steps exceeding two.
• any washing techniques for washing fiber tows that are known per se in the art, can be used for in the washing line 19.
• the transporting means for the fiber tow such as rollers and godets or the like, in the washing line are operated at a constant speed so that the tension is kept essentially constant and no further stretching of the fibers in the fiber tow occurs. This also keeps the orientation of the fibers essentially at the state they were when leaving the second godet 18 after the stretching within the conditioning bath.
• the fiber tow 15 is directed to a cutter 21, which cuts the fiber tow into staple fibers 22.
• a cutter 21 which cuts the fiber tow into staple fibers 22.
• the consistency of the fibers has sufficiently settled so that the fibers essentially keep their cellulose specific diameter, elongation and orientation even if they are cut in wet or never-dried state. Therefore, it is not necessary to dry the fiber tow 15 before cutting, which can reduce costs and allows for the implementation of more efficient post-processing steps.
• a post-processing facility for the cut staple fibers is shown.
• the cut staple fibers are transported (or fall) from the cutter 21 to a fleece-forming device 23 having a basin 24 filled with a liquid, e.g. water, and a conveyer belt 25.
• the conveyer belt 25 is permeable to liquid and a current is maintained in the basin that transports the fibers that are suspended in the liquid of the basin to the conveyer belt 25, where they are collected and form a non-woven fiber layer 26 on the top surface of the conveyer belt 25.
• the surface of the conveyor belt is tilted and transports the newly formed non-woven fiber layer 26 out of the liquid and to further transport equipment (which is, for reasons of conciseness, not shown in Fig. 2).
• the freshly cut staple fibers 22 should be regularly distributed across the width of the fleece-forming device 23 so that the non-woven fiber layer 26 has a uniform width and consistency.
• the non-woven fiber layer 26 is squeezed in a first pressing device 27a to remove some of the liquid in the non-woven fiber layer 26.
• a first pressing device 27a to remove some of the liquid in the non-woven fiber layer 26.
• further pressing devices 27b to 27e can be arranged downstream between several processing steps. Especially the first pressing device 27a, but also the other pressing devices, create a natural crimp on the fibers in the non-woven fiber layer which is preferable for many fiber appliances.
• the post-processing that is performed on the non-woven fiber layer 26, as it is shown in Fig. 2, comprises a neutralizer 28, a bleaching facility 29, a crosslinking facility 30, a finishing facility 31, an opener 32, a dryer 33 and a baling press 34.
• the fibers that may still contain residues of alkali are neutralized with an acidic liquid, which can be selected from a list comprising diluted acetic acid, lactic acid, sulphuric acid or the like. Depending on the specific processing conditions, a neutralizing step may not always be necessary.
• the fibers in the non-woven fiber layer 26 are then bleached in bleaching facility 29. If appropriate, a further washing step (not shown in Fig. 2) can be implemented between the neutralizer 28 and the bleaching facility 29.
• the used water of this (and any other) washing step can be forwarded to upstream washing steps and/or the cutter 21 of the washing line 19 in the form of a countercurrent washing system.
• a crosslinking agent can be applied to the fibers in order to reduce fibrillation of the fibers and improve the processing and handling of the fibers in the textile chain.
• a finishing agent or soft finish can be applied to the fibers.
• the non-woven fiber layer 26 After dewatering the non-woven fiber layer 26 in the pressing device 27e the non-woven fiber layer 26 is fed into an opener 32, which loosens and opens the structure of the fiber layer 26 to improve the drying efficiency in the following dryer 33 and also to improve the further processing of the finished staple fibers.

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• 2021
  • 2021-07-26 EP EP21187680.0A patent/EP4124681A1/de not_active Withdrawn
• 2022
  • 2022-07-22 CA CA3226776A patent/CA3226776A1/en active Pending
  • 2022-07-22 WO PCT/EP2022/070609 patent/WO2023006601A1/en active Application Filing
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