US20150111450A1 - Polyesters and fibers made therefrom - Google Patents

Polyesters and fibers made therefrom Download PDF

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Publication number
US20150111450A1
US20150111450A1 US14/385,903 US201314385903A US2015111450A1 US 20150111450 A1 US20150111450 A1 US 20150111450A1 US 201314385903 A US201314385903 A US 201314385903A US 2015111450 A1 US2015111450 A1 US 2015111450A1
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Prior art keywords
fiber
polymer
ptf
poly
furandicarboxylate
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Fredrik Nederberg
Bhuma Rajagopalan
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EIDP Inc
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EI Du Pont de Nemours and Co
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Priority to US14/385,903 priority Critical patent/US20150111450A1/en
Assigned to E. I. DU PONT DE NEMOURS AND COMPANY reassignment E. I. DU PONT DE NEMOURS AND COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NEDERBERG, FREDRIK, RAJAGOPALAN, BHUMA
Publication of US20150111450A1 publication Critical patent/US20150111450A1/en
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    • 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
    • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C08G63/12—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from polycarboxylic acids and polyhydroxy compounds
    • C08G63/16—Dicarboxylic acids and dihydroxy compounds
    • C08G63/18—Dicarboxylic acids and dihydroxy compounds the acids or hydroxy compounds containing carbocyclic rings
    • C08G63/181—Acids containing aromatic rings
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • 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
    • D01F6/78—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products
    • D01F6/84—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from copolyesters
    • 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
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • 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
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/061—Load-responsive characteristics elastic
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • 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.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • 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.]
    • Y10T442/40—Knit fabric [i.e., knit strand or strip material]
    • 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]

Definitions

  • This invention relates in general to fibers prepared from polyesters and in particular poly(trimethylene-2,5-furandicarboxylate) (PTF) and PTF based blends and copolymers.
  • PTF poly(trimethylene-2,5-furandicarboxylate)
  • Synthetic fibers are found in many essential applications ranging from apparel to carpets to automobile interiors.
  • Polypropylene (PP), polyethylene terephthalate (PET) and polyamides (nylon-6 and nylon-6,6) are frequently used polymers in such applications and while manufacturing routes and applications have been developed during the past several decades, these polymers are all derived from fossil fuel.
  • the polymer produced from FDCA and Bio-PDOTM PolyTrimethylene-2,5-Furandicarboxylate (PTF)
  • FDCA and Bio-PDOTM PolyTrimethylene-2,5-Furandicarboxylate (PTF)
  • PPF PolyTrimethylene-2,5-Furandicarboxylate
  • a fiber comprising a polymer, wherein the polymer comprises poly(alkylene furandicarboxylate) obtained by polymerization of a reaction mixture comprising a furan dicarboxylic acid and a C 2 to C 12 aliphatic diol.
  • a fiber of the present invention is obtained from a polymer composition which is a polymer blend comprising poly(trimethylene-2,5-furandicarboxylate), alternatively referred to herein as PTF, and a second poly(alkylene-furandicarboxylate) that is different from PTF, and wherein the second poly(alkylene-furandicarboxylate) is derived from furan dicarboxylic acid and an aliphatic diol selected from the group consisting of ethylene glycol and C 4 to C 12 aliphatic diols.
  • a fiber of the present invention is obtained from a polymer blend comprising PTF and poly(alkylene terephthalate), wherein the poly(alkylene terephthalate) comprises a C 2 to C 12 aliphatic diol moiety.
  • a fiber of the present invention is obtained from a copolymer comprising of 2,5-furandicarboxylate, terephthalate and 1,3 propane diol monomer units.
  • the molar ratio of 2,5-furan dicarboxylic acid to other diacids can be any range, for example the molar ratio can be greater than 1:100 or alternatively in the range of 1:100 to 100 to 1 or 1:9 to 9:1 or 1:3 to 3:1 or 1:1 in which the diol is added at an excess of 1.2 to 3 equivalents to total diacids charged.
  • FIG. 1 schematically illustrates an exemplary apparatus for spinning either spun-drawn or partially oriented yarn.
  • FIG. 2 is a schematic illustration of an exemplary press spinning unit.
  • a fiber comprising a polymer, wherein the polymer comprises poly(alkylene furandicarboxylate) derived from the polymerization of furan dicarboxylic acid and a C 2 to C 12 aliphatic diol.
  • Poly(alkylene-furandicarboxylate) can be prepared from a C 2 to C 12 aliphatic diol and from 2,5-furan dicarboxylic acid or a derivative thereof.
  • the aliphatic diol is a biologically derived C 3 diol, such as 1, 3 propane diol.
  • alkylene substituents such as, for example, —CH 3 , —C 2 H 5 , or a C 3 to C 25 straight-chain, branched or cyclic alkane group, optionally containing one to three heteroatoms selected from the group
  • carboxylic acid derivatives such as acid halides, carboxylic acid esters, and carboxylic acid anhydrides can be useful functional equivalents of either or both of the carboxylic acid moieties of the furan. That is, these functionally equivalent groups can be used to obtain the polymeric fiber of the presently claimed invention when reacted with C 2 to C 12 aliphatic diols.
  • carboxylic acid groups of the furan dicarboxylic acid will be referred to as “acid” or “diacid” groups, but for the purposes of the present invention, such reference will also incorporate any conventional functional equivalent of a carboxylic acid.
  • biologically-derived and “bio-derived” are used interchangeably and refer to chemical compounds including monomers and polymers, that are obtained from plants and contain only renewable carbon—that is carbon obtained from a source that can be regenerated, for example, from crops—and not fossil fuel-based or petroleum-based carbon.
  • bio-derived materials have less impact on the environment as their creation does not deplete diminishing fossil fuels and, upon degradation, releases carbon back to the atmosphere for use by plants once again.
  • Suitable C 2 to C 12 aliphatic diol include, but are not limited to, ethylene glycol, diethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,4-cyclohexanedimethanol, and 2,2-dimethyl-1,3-propanediol.
  • an aliphatic diol can be 1,3-propanediol (Bio-PDOTM) that is biologically derived and is polymerized with a furan 2,5-dicarboxyl derivative, whereby the polymer shown below (poly(trimethylene-2,5-furandicarboxylate), known alternatively herein as PTF, can be obtained:
  • n 10-1000 or 50-500 or 25-185 or 80-185.
  • Other variations of PTF can be obtained by using 1,2-propanediol, or by using mixtures of the two propanediols.
  • the polymer in a fiber of the present invention, can have a number average molecular weight (Mn) in the range of 10,000-12,000, or in the range of 10,000-13,000, or in the range of 10,000-14,000, or in the range of 10,000-15,000, or in the range of 10,000-16,000, or in the range of 10,000-17,000, or in the range of 10,000-18,000, or in the range of 10,000-19,000, or in the range of 10,000-20,000, or in the range of 10,000-21,000, or in the range of 4900-196,000.
  • Mn number average molecular weight
  • Desirable molecular weight for a polymer composition useful in the practice of the present invention can depend on the final application or use of the fiber.
  • a fiber of the present invention can have a modulus in the range of 10-100 g/den, or in the range of 30-100 g/den, or in the range of 35-100 g/den, or in the range of 40-100 g/den, or in the range of 45-100 g/den, or in the range of 50-100 g/den, or in the range of 55-100 g/den.
  • a fiber of the present invention can have a tenacity in the range of about 0.2-5 g/den, or in the range of 0.8-5 g/den, or in the range of about 1.0-5 g/den, or in the range of 1.2-5 g/den, or in the range of 1.4-5 g/den, or in the range of 1.6-5 g/den, or in the range of 1.8-5, or in the range of 2.0-5 g/den, or in the range of 2.2-5 g/den, or in the range of 2.4-5 g/den, or in the range of about 2.6-5 g/den, or in the range of 2.8-5 g/den, or in the range of 3.0-5 g/den
  • the tenacity will have a tendency to increase until a plateau is reached. Therefore tenacity, as it may relate to molecular weight of the polymer, can be manipulated by varying the molecular weight within the broad range described herein.
  • a fiber of the present invention can have a percent elongation in the range of 5-500, or in the range of 25-500, or in the range of 30-500, or in the range of about 35-500, or in the range of 40-500, or in the range of 45-500, or in the range of 50-500, or in the range of 55-500, or in the range of 60-500, or in the range of 65-500, or in the range of 70-500, or in the range of 75-500, or in the range of 80-500, or in the range of 85-500, or in the range of 90-500, or in the range of 95-500, or in the range of 100-500, or in the range of 150-500, or in the range of 200-500.
  • Percent elongation as it may relate to molecular weight of the polymer, therefore can be manipulated by varying the molecular weight within the broad range described herein.
  • a fiber of the present invention can be oriented or not oriented, and a polymer suitable for use in the practice of the present invention can be amorphous or crystalline. It can be useful to orient fibers in applications such as apparel or carpets. Alternatively, fibers that are not oriented can be useful in such applications as staple.
  • a polymer as described herein has a heat of crystallization less than 1 J/g or less than 10 J/g or less than 100 J/g, as measured by differential scanning calorimetry with heating rates of 10° C./min.
  • the polymer consists essentially of poly(trimethylene-2,5-furandicarboxylate) (PTF) and is amorphous.
  • Crystalline polymers can be suitable for preparing fibers of the present invention, and such fibers can be useful in such applications as apparel and carpets.
  • amorphous polymers can provide fibers of the present invention that are suitable for use in such applications as disposable garments, for example medical gowns, protective apparel, disposable gloves, diapers.
  • the polymer is a polymer blend comprising poly(trimethylene-2,5-furandicarboxylate) and a second poly(alkylene-furandicarboxylate) that is different from the PTF, wherein the poly(alkylene-furandicarboxylate) is obtained by polymerization of a furan dicarboxylic acid and an aliphatic diol selected from the group consisting of ethylene glycol, and C 4 to C 12 diols, or mixtures thereof.
  • the polymers can be blended in any proportion in order to provide a fiber having properties desirable in a given fiber application.
  • One of ordinary skill in the art would understand how to obtain desirable fiber properties by using different proportions of materials to achieve the properties needed from the blend.
  • a blend useful for preparing a fiber of the present invention can have from about 0.1 to about 99.9% or from about 5 to about 75% or from about 10 to about 50% by weight of PTF based on the total weight of the blend, in order to obtain a fiber having desirable modulus, elongation, tenacity, crystallinity.
  • a fiber of the present invention is obtained from a polymer blend comprising poly(trimethylene-2,5-furandicarboxylate) and poly(alkylene terephthalate).
  • the polymers can be blended in any proportion in order to provide a fiber having properties desirable in a given fiber application.
  • One of ordinary skill in the art would understand how to obtain desirable fiber properties by blending different proportions of materials.
  • a blend useful for preparing a fiber of the present invention can have from about 0.1 to about 99.9% or alternatively from about 5 to about 75% or from about 10 to about 50% by weight of PTF based on the total weight of the blend, in order to obtain a fiber having desirable modulus, elongation, tenacity, crystallinity.
  • a fiber of the present invention can be obtained from a random or block copolymer comprising 2,5-furandicarboxyl, terephthalate and Bio-PDOTM monomer units.
  • the monomers can be reacted in any proportion in order to provide a fiber having properties desirable in a given fiber application.
  • One of ordinary skill in the art would understand how to obtain desirable fiber properties by using different proportions of materials to achieve the properties of the fiber which are desired.
  • a copolymer useful for preparing a fiber of the present invention can have from about 0.1 to about 99.9% or alternatively from about 5 to about 75% or alternatively from about 10 to about 50% by weight of PTF-based repeat units based on the total weight of the copolymer, in order to obtain a fiber having desirable modulus, elongation, tenacity, crystallinity.
  • PTF-based repeat units include a diol and a furanyl dicarboxylate moiety.
  • the molar ratio of 2,5-furan dicarboxylic acid to other diacids can be any ratio that provides a fiber having the desirable properties for the intended fiber application.
  • the molar ratio can be greater than 1:100 or alternatively in the range of from about 1:100 (2,5-furan dicarboxylic acid):(other acid) to 100:1 or 1:9 to 9:1 or 1:3 to 3:1 or 1:1 in which the diol is added at an excess of 1.2 to 3 equivalents to total diacids charged.
  • diols and polyols useful as monomers in the practice of the present invention include, for example, 1,4-benzenedimethanol, poly(ethylene glycol), poly(tetrahydrofuran), 2,5-di(hydroxymethyl)tetrahydrofuran, isosorbide, glycerol, pentaerythritol, sorbitol, mannitol, erythritol, and threitol.
  • polyfunctional aromatic acids suitable for use in the practice of the present invention include, for example, terephthalic acid, isophthalic acid, adipic acid, azelic acid, sebacic acid, dodecanoic acid, 1,4-cyclohexane dicarboxylic acid, maleic acid, succinic acid, naphthalene dicarboxylic acid, and 1,3,5-benzenetricarboxylic acid.
  • Hydroxy acids can be suitable comonomers having both hydroxyl and acid functionality for use in the practice of the present invention to form copolymers, and thereby form covalent linkages with acid and/or hydroxyl functional moieties in the polymerization mixture.
  • suitable hydroxy acids include but are not limited to, glycolic acid, hydroxybutyric acid, hydroxycaproic acid, hydroxyvaleric acid, 7-hydroxyheptanoic acid, 8-hydroxycaproic acid, 9-hydroxynonanoic acid, or lactic acid; or those derived from pivalolactone, ⁇ -caprolactone or L,L, D,D or D,L lactides.
  • Exemplary copolymers derived from 2,5-furan dicarboxylic acid, at least one of a diol or a polyol monomer, and at least one of a polyfunctional aromatic acid or a hydroxyl acid include, but are not limited to copolymer of 1,3-propanediol, 2,5-furandicarboxylic acid and terephthalic acid; copolymer of 1,3-propanediol, 2,5-furandicarboxylic acid and succinic acid; copolymer of 1,3-propanediol, 2,5-furandicarboxylic acid; copolymer of 1,3-propanediol, 2,5-furandicarboxylic acid and adipic acid; copolymer of 1,3-propanediol, 2,5-furandicarboxylic acid and sebacic acid, copolymer of 1,3-propanediol, 2,5-furandicarboxylic acid
  • the intrinsic viscosity of the poly(trimethylene-2,5-furandicarboxylate) is at least 0.3 dl/g, or at least 0.5 dl/g or at least 0.6 dl/g and most preferably at least 0.7 dl/g.
  • the intrinsic viscosity of the disclosed polymer composition is up to about 0.52 dl/g, or up to 0.7 dl/g, or up to about 0.92 dl/g.
  • Additives including delusterants, heat stabilizers, viscosity boosters, optical brighteners, pigments, and antioxidants, can be used.
  • TiO 2 or other pigments can be added, such as described in U.S. Pat. Nos. 3,671,379, 5,798,433 and 5,340,909, EP 699 700 and 847 960, and WO 00/26301, which are incorporated herein by reference.
  • fibers reference is made to items recognized in the art as fibers, such as continuous filaments, monofilament, staple, etc.
  • the fibers can be round or have other shapes, such as octalobal, delta, sunburst (also known as sol), scalloped oval, trilobal, tetra-channel (also known as quatra-channel), scalloped ribbon, ribbon, starburst, etc.
  • They can be solid, hollow or multi-hollow. They can be used to prepare fabrics or textiles, carpets (from bulked continuous filaments and staple), and other products. Fabrics include knitted, woven and nonwoven fabrics.
  • the fibers may be produced from the PTF homopolymer or from blends comprising PTF and copolymers comprising of PTF repeat units.
  • the fiber of the present invention can have fiber denier of less than 1 or less than 50.
  • a fiber as disclosed herein can be, and more typically is, a continuous filament fiber.
  • the fiber can be a discontinuous filament fiber that is composed of pieces of entangled filament, and such a fiber can have an length/diameter ratio (L/D) of about 20-60.
  • Yarns as formed from such fibers are typically long unbroken lengths of continuous filament fiber in which the fibers are bonded or interlocked together and are typically not twisted.
  • a yarn can be prepared from a fiber hereof by providing forward or reverse twist therein, and this is more often the case if the fiber used is a discontinuous filament fiber.
  • PTF poly(ethylene glycol)
  • the various polymers used in a fiber hereof include polyesters, and also various copolymers (random or block), that may be made according to the selection of which monomers are used for polymerization.
  • the polymer can be prepared from a C 2 to C 12 aliphatic diol and from 2,5-furan dicarboxylic acid or a derivative thereof.
  • Aliphatic diol is a biologically derived C 3 diol, such as 1,3 propane diol.
  • alkylene substituents such as, for example, —CH 3 , —C 2 H 5 , or a C 3 to C 25 straight-chain, branched or cyclic alkane group, optionally containing one to three heteroatoms selected from the group
  • a polymer for use herein can be made by a two-step process, wherein first a prepolymer is made having a 2,5-furandicarboxylate moiety within the polymer backbone.
  • This intermediate product is preferably an ester composed of two diol monomers and one diacid monomer, wherein at least part of the diacid monomers comprises 2,5-FDCA, followed by a melt-polymerization of the prepolymers under suitable polymerization conditions.
  • Such conditions typically involve reduced pressure to remove the excess of diol monomers.
  • Esters of 2,5 furan dicarboxylic acid or the diacid itself or mixtures of both may be used.
  • step (I) dimethyl-2,5-furandicarboxylate is reacted in a catalyzed transesterification process with about 2 equivalents of a diol, to generate the prepolymer while removing 2 equivalents of methanol.
  • Dimethyl-2,5-furandicarboxylate is preferred, as this transesterification step generates methanol, a volatile alcohol that is easy to remove.
  • diesters of 2,5-FDCA with other volatile alcohols or phenols e.g. having a boiling point at atmospheric pressure of less than 150° C., preferably less than 100° C., more preferably of less than 80° C. may be used as well.
  • Preferred examples therefore include ethanol, methanol and a mixture of ethanol and methanol.
  • the aforementioned reaction leads to a polyester.
  • the diol monomers may if desired contain additional hydroxyl groups, such as glycerol, pentaerythritol or sugar alcohols.
  • the furan diacid may also be used directly, or converted to the diester or can be added along with the diester.
  • Step (II) of this process is a catalyzed polycondensation step, wherein the prepolymer is polycondensed under reduced pressure, at an elevated temperature and in the presence of a suitable catalyst.
  • the first step is a transesterification step, catalyzed by a specific transesterification catalyst at a temperature preferably in the range of from about 150-260° C., more preferably in the range of from about 180-240° C. and carried out until the starting ester content is reduced until it reaches the range of about 3 mol % to less than about 1 mol %.
  • the transesterification catalyst may be removed, to avoid interaction in the second step of polycondensation, but typically is included in the second step.
  • the selection of the transesterification catalyst is therefore effected by the selection of the catalyst used in the polycondensation step.
  • Tyzor® organic titanates and zirconates catalysts such Tyzor® TPT, Tyzor® TBT can be used.
  • Tin(IV) based catalysts preferably organotin(IV) based catalysts such as alkyltin(IV) salts including monoalkyltin(IV) salts, dialkyl and trialkyltin(IV) salts and mixtures thereof, can also be used as transesterification catalysts, that are better than tin(II) based catalysts such as tin(II) octoate.
  • These tin(IV) based catalysts may be used with alternative or additional transesterification catalysts.
  • Antimony based catalysts can also be used.
  • transesterification catalysts examples include one or more of titanium(IV) alkoxides or titanium(IV) chelates, zirconium(IV) chelates, or zirconium(IV) salts (e.g. alkoxides); hafnium(IV) chelates or hafnium(IV) salts (e.g. alkoxides).
  • transesterification catalysts are butyltin(IV) tris(octoate), dibutyltin(IV) di(octoate), dibutyltin(IV) diacetate, dibutyltin(IV) laureate, bis(dibutylchlorotin(IV)) oxide, dibutyltin dichloride, tributyltin(IV) benzoate and dibutyltin oxide, antimony oxides.
  • the active catalyst as present during the reaction may be different from the catalyst as added to the reaction mixture.
  • the catalysts are used in an amount of about 0.01 mol % relative to initial diester to about 0.2 mol % relative to initial diester, more preferably in an amount of about 0.04 mol % of initial diester to about 0.16 mol % of initial diester.
  • the intermediate product is used as such in the subsequent polycondensation step.
  • the prepolymer is polycondensed under reduced pressure, at an elevated temperature and in the presence of a suitable catalyst.
  • the temperature is preferably in the range of about the melting point of the polymer to about 30° C. above this melting point, but preferably not less than about 180° C.
  • the pressure should be reduced preferably gradually. It should preferably be reduced to as low as possible, more preferably below 1 mbar.
  • This second step is preferably catalyzed by a polycondensation catalyst such as one of those listed below, and the reaction is preferably carried out at mild melt conditions.
  • suitable polycondensation catalysts include titanium(IV) alkoxides or titanium(IV) chelates, zirconium(IV) chelates, or zirconium(IV) salts (e.g. alkoxides); hafnium(IV) chelates or hafnium(IV) salts (e.g.
  • tin(II) salts such as tin(II) oxide, tin(II) dioctoate, butyltin(II) octoate, or tin(II) oxalate.
  • Various catalysts include tin(II) salts obtained by the reduction of the tin(IV) catalyst, e.g. alkyltin(IV), dialkyltin(IV), or trialkyltin(IV) salts, antimony based salts Additional catalyst can be added prior to the condensation reaction to increase reaction efficacy, which can be used as transesterification catalyst with a reducing compound. Reducing compounds used may be well-known reducing compounds, preferably phosphorus compounds.
  • Particularly preferred reducing compounds are organophosphorus compounds of trivalent phosphorus, in particular a monoalkyl or dialkyl phosphinate, a phosphonite or a phosphite.
  • suitable phosphorus compounds are triphenyl phosphite, diphenyl alkyl phosphite, phenyl dialkyl phosphite, tris(nonylphenyl)phosphite, trilauryl phosphite, trioctadecyl phosphite, distearyl pentaerythritol diphosphite, tris(2,4-di-tert-butylphenyl)phosphite, diisodecyl pentaerythritol diphosphite, di(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, tristearylsorbitol triphosphite,
  • Suitable catalysts therefore include tin(II) salts such as tin(II) dioctoate, butyl(II) octoate and other alkyltin(II) octoate compounds, prepared from the corresponding tin(IV) salt using e.g. a trialkyl phosphite, a monoalkyl diaryl phosphite, a dialkyl monoaryl phosphite or a triaryl phosphite.
  • the reducing compound is added in the melt of the prepolymer. The addition of the reducing compound at this stage will avoid discoloration of the polymer product and increase molecular weight of the polymer.
  • the catalysts are used in an amount of about 0.01 mol % relative to initial diester to about 0.2 mol % relative to initial diester, more preferably in an amount of about 0.04 mol % of initial diester, to about 0.16 mol % of initial diester.
  • solid state polymerization processes pellets, granules, chips or flakes of polymer are subjected for a certain amount of time to elevated temperatures (below melting point) in a hopper, a tumbling drier or a vertical tube reactor or the like.
  • elevated temperatures below melting point
  • a tumbling drier or a vertical tube reactor or the like.
  • titanium based catalysts during SSP of the FDCA-based polymers has enabled the polymer to reach a number average molecular weight of 20,000 and greater.
  • the temperature should be elevated but nonetheless remain (well) below the melting point of the polymer.
  • a method of making a fiber comprising providing a polymer composition comprising poly(alkylene furandicarboxylate) derived from furan dicarboxylic acid and a C 2 to C 12 aliphatic diol and spinning the polymer composition to form fibers, such that the highest temperature applied to the polymer during spinning is in the range of about 210-250° C.
  • the highest temperature applied to the polymer during spinning is in the range of 210° C.-215° C., or in the range of 210-220° C., or in the range of 210-225° C., or in the range of 210-230° C., or in the range of 210-235° C., or in the range of 210-240° C., or in the range of 210-245° C., or in the range of 210-265° C.
  • the step of providing a polymer composition comprises providing a polymer blend comprising poly(trimethylene-2,5-furandicarboxylate) and poly(alkylene-furandicarboxylate), as disclosed supra.
  • the step of providing a polymer composition comprises providing a polymer blend comprising poly(trimethylene-2,5-furandicarboxylate) and poly(alkylene terephthalate), as disclosed supra.
  • the step of providing a polymer composition comprises providing a copolymer derived from 2,5-furan dicarboxylic acid at least one of a diol or a polyol monomer, as disclosed supra.
  • FIG. 1 schematically illustrates an exemplary apparatus for spinning either spun-drawn or partially oriented yarn, which is useful in the process of the spinning disclosed fiber.
  • An exemplary process using the exemplary apparatus shown in FIG. 1 is disclosed infra in Example 1.
  • FIG. 2 is a schematic illustration of an exemplary press spinning unit, which is useful in the process of the spinning disclosed fiber.
  • An exemplary process using the exemplary apparatus shown in FIG. 2 is disclosed infra in Example 4.
  • the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion.
  • a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
  • “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
  • one or more of A, B, and C implies any one of the following: A alone, B alone, C alone, a combination of A and B, a combination of B and C, a combination of A and C, or a combination of A, B, and C.
  • the examples cited here relate to tannin-based foams.
  • the discussion below describes how PTF based polymers, copolymers and blends and fibers made therefrom are formed.
  • the software for data acquisition and reduction was Astra® version 5.4 by Wyatt.
  • the columns used were two Shodex GPC HFIP-806MTM styrene-divinyl benzene columns with an exclusion limit of 2 ⁇ 10 7 and 8,000/30 cm theoretical plates; and one Shodex GPC HFIP-804MTM styrene-divinyl benzene column with an exclusion limit 2 ⁇ 10 5 and 10,000/30 cm theoretical plates.
  • the specimen was dissolved in 1,1,1,3,3,3-hexafluoro-2-propanol (HFIP) containing 0.01 M sodium trifluoroacetate by mixing at 50° C. with moderate agitation for four hours followed by filtration through a 0.45 ⁇ m PTFE filter. Concentration of the solution was circa 2 mg/mL.
  • HFIP 1,1,1,3,3,3-hexafluoro-2-propanol
  • Intrinsic viscosity was determined using the Goodyear R-103B Equivalent IV method, using T-3, Selar® X250, Sorona®64 as calibration standards on a Viscotek® Forced Flow Viscometer Modey Y-501C. Methylene chloride/trifluoro acetic acid was the solvent carrier.
  • T g Glass transition temperature
  • T m melting point
  • Fiber tenacity was measured on a Statimat ME fully automated tensile tester. The test was run according to an automatic static tensile test on yarns with a constant deformation rate according to ASTM D 2256.
  • WAXS Wide angle X-ray scattering
  • CI crystallinity index
  • the data are collected in reflection geometry.
  • the diffraction scan range is 4 to 40 degrees two-theta with a step size of 0.05 degrees.
  • the sample is rotated 2 seconds per revolution with a counting time of 5 seconds per step.
  • TBT catalyst titanium(IV)isobutoxide
  • TPT catalyst titanium(IV)isopropoxide
  • ethylene glycol 1-4-butanediol
  • PTMEG polytetramethyleneglycol 1000 g/mol
  • TMTM trimethyltrimellitate
  • FDME 2,5-furandimethylester
  • Ethylene copolymer Surlyn® 8920, Polytrimethylene terephthalate (Sorona®, PTT, J1156, 0.96IV) and bio 1,3-propane diol (Bio-PDOTM) were provided from the DuPont company and was used as received.
  • Dovemox-10 was obtained from Dovemox® and used as received.
  • the formed polymer was recovered by pushing the melt through an exit valve at the bottom of the vessel and into a water quench bath.
  • the thus formed strand was strung through a pelletizer, equipped with an air jet to dry the polymer free from moisture, cutting the polymer strand into chips approximately 1 ⁇ 4 inch long and approximately 1 ⁇ 8 inch in diameter. Yield was approximately 2724 g (approximately 5 lbs).
  • T g was ca. 58° C. (DSC, 5° C./min, 2 nd heat)
  • T m was ca. 176° C. (DSC, 5° C./min, 2 nd heat).
  • 1 H-NMR (TCE-d) ⁇ : 7.05 (s, 2H), 4.40 (m, 4H), 2.15 (m, 2H).
  • M n (SEC) approximately 10 300 D, PDI 1.97. IV approximately 0.55 dL/g.
  • PTF pre- SPP polymer temp SPP reaction M n IV Polymer used (° C.) time (hrs) (g/mol) 1 PDI 1 (dL/g) 2 PTF_1 PTF_1p 163 423 11 500 1.91 0.52 PTF_2 PTF_2p 163 423 13 900 2.09 0.70 PTF_3 PTF_3p 163 256 18 100 1.95 0.78 PTF_4 PTF_4p 165 290 n/a n/a 0.92 1 from SEC, 2 from intrinsic viscosity.
  • Pellets of polymer prepared as described above were melt spun into spun-drawn, or partially oriented fibers.
  • the pellets were fed using a K-Tron weight loss feeder to a 28 millimeter diameter twin screw extruder operating at ca. 30-50 rpm to maintain a die pressure between 400-1100 psi.
  • the extruder has nine heated barrel zones and the polymer was extruded with the following temperature settings: 100/150/230/230/230/230/230/230/230/230° C.
  • a Zenith metering pump conveyed the melt to the spinneret at a throughput of approximately 10.5 g/min, the transfer line temperature was held at 240° C.
  • the molten polymer from the metering pump was forced through a 4 mm glass bead, one 50 mesh, and five 200 mesh screens, to a 10 hole (d/l, 12/30 mills) or 17 hole (d/l, 12/48 mills or d/l, 15/90 mills) round spinneret, 301 , heated to 240° C.
  • the filament stream leaving the spinneret, 302 were passed through an air quench zone, 303 , where they were impinged upon a transverse air stream at 21° C.
  • the filaments were then passed over a spin finish head, 304 , where a spin finish was applied (1 wt % finish on yarn), and the filaments were converged to form a yarn.
  • the yarn so formed was conveyed via a tensioning roll, 305 , onto two non-heated feed rolls (godets), 306 , and then onto two non-heated draw rolls (godets), 308 , via a steam jet, 307 , operating at a temperature of 130° C. and a pressure of 30 psi.
  • the filaments were passed onto two annealing rolls (godets), 309 , and to a pair of let-down rolls, 310 , and collected on a winder, 311 .
  • the spinneret pack top and band
  • the die was set at 240° C.
  • a winder, 312 was added after the feed rolls, 306 , and non-drawn yarn collected at various wind-up speeds.
  • PTF of varying molecular weights can be successfully spun into fibers at various draw ratios to produce filaments with a steam assisted draw. Obtained filaments are strong, pliable and have measured mechanical properties similar to commercial fibers based on PET or Sorona®.
  • One unexpected result was the ability to successfully spin the low molecular weight PTF grade (PTF-1).
  • Another unexpected finding are the relatively high fiber mechanical despite a low crystalline content of the filaments. All measured crystallinity indexes using WAXS were close to zero.
  • PTF can be successfully spun into fibers using heated draw rolls and using two-staged draw to produce filaments. Obtained filaments are strong, pliable and have measured mechanical properties similar to commercial fibers based on PET or Sorona®. All measured crystallinity indexes using WAXS were close to zero.
  • Partially oriented yarn is produced by directly winding the yarn after the feed roll without any drawing winder, These non-drawn yarns were collected at various wind-up speeds.
  • Table 7 shows that PTF can be converted into Partially Oriented Yarn (POY).
  • POY Partially Oriented Yarn
  • a compound of PTF — 4 and Surlyn®8920 pellets were made prior to melt spinning. Here PTF — 4 pellets and Surlyn®8920 pellets were fed to provide a concentration of 10 or 20% of Surlyn®8920 based upon the total weight of the blend. The thus combined pellets were mixed in a plastic bag by shaking and tumbling by hand.
  • the thus mixed batch was placed into a K-Tron T-20 (K-Tron Process Group, Pittman, N.J.) weight loss feeder feeding a PRISM laboratory co-rotating twin screw extruder (available from Thermo Fisher Scientific, Inc.) equipped with a barrel having four heating zones and a diameter of 16 millimeter fitted with a twin spiral P1 screw.
  • the extruder was fitted with a 3/16′′diameter circular cross-Section single aperture strand die.
  • the nominal polymer feed rate was 8 lbs/hr.
  • the first barrel Section was set at 180° C. and the subsequent three barrel Sections and the die were set at 230° C.
  • the screw speed was set at 150 rpm.
  • the melt temperature of the extrudate was determined to be 236° C.
  • thermocouple probe into the melt as it exited the die.
  • the thus extruded monofilament strand was quenched in a water bath. Air knives dewatered the strand before it was fed to a cutter that sliced the strand into about 2 mm length blend pellets.
  • the thus prepared compound was dried and fed into the melt spinning extruder to provide a final concentration of Surlyn®8920 as provided in Table 9.
  • Table 9 shows feasibility of producing spun yarn using PTF with nucleating agents such as Surlyn® 8920 to produce filaments that are strong, pliable and have measured mechanical properties similar to commercial fibers based on PET or Sorona®. While filaments with 2 wt % Surlyn®8920 had measured crystallinity indexes using WAXS close to zero filaments with 4 wt % Surlyn®8920 had a measured crystallinity of 0.05 (sample 3.8) demonstrating an ability to nucleate PTF crystallization in a spinning operation.
  • nucleating agents such as Surlyn® 8920
  • Bio-PDOTM 110.6 g, 1.454 mol
  • FDME 133.8 g, 0.727 mol
  • PTMEG 1.5 g, 1.5 mmol
  • TMTM 162 mg, 0.63 mmol
  • TBT catalyst [0.3 g or 0.31 mL] was added after the first evacuation.
  • the flask was immersed into a preheated metal bath set at 160° C. and allowed to equilibrate for 20 minutes to melt the solids.
  • the temperature was increased to 180° C. and held for 60 minutes after which the temperature was increased to 210° C. and held for an additional 60 minutes to complete the ester interchange and distillation of methanol.
  • the nitrogen purge was closed and a vacuum ramp started, after about 60 minutes the vacuum reached a value of 50-60 mTorr.
  • the temperature was increased to 230° C. and the reaction held under vacuum for 3 hours with stirring at 50-180 rpm.
  • the torque was monitored (readings at 180 rpm) and the polymerization was stopped by removing the heat source.
  • the over head stirrer was stopped and elevated from the floor of the reaction vessel before the vacuum was turned off and the system purged with N 2 gas.
  • the kettle reactor was separated and the product decanted and allowed to cool under a purge of nitrogen.
  • the recovered polymer was chopped into pellets using a Wiley mill that was cooled with liquid nitrogen. The so produced polymer pellets were dried under vacuum and a weak nitrogen stream at 120° C. for 24 hours.
  • the recovered yield was approximately 70%, or approximately 100 g.
  • T g was approximately 55° C.
  • T m was approximately 161° C. (second heating, 10° C./min).
  • the polymer Prior to entering the spinneret, the polymer passed through a filter pack containing one 50 and three 200 mesh screens, not shown. The melt was extruded into a single strand of fiber, 409 , at a rate of 0.4 g/min. The extruded fiber was passed through a transverse air quench zone, 410 , and thence to a wind-up, 411 . Optionally a draw step was included in which the filament was fed onto a cold feed roll, over a heated pin and onto a cold draw roll, and to a wind-up. A summary of conditions is given in Table 10 below.
  • Table 10 shows feasibility of producing a spun single filament from a copolymer of FDCA, Bio-PDO® and PTMEG. While the incorporation of 1 wt % PTMEG accelerates the ability of PTF to crystallize in a DSC pan during a 10° C./min heating scan the produced single filament was shown to be amorphous since the measured crystallinity index (WAXS) was close to zero.
  • WAXS measured crystallinity index
  • Ethylene glycol (84.2 g, 1.357 mol) and FDME (125 g, 0.678 mol) were polymerized in the same setup as used in A above using Tyzor®TPT as catalyst (76 ⁇ L). The only difference was that the ester interchange was made at 180° C. for 60 minutes and 200° C. for 60 minutes. The recovered polymer yield was approximately 63 g. T g was approximately 89° C., T m was approximately 214° C. (second heating, 10° C.). 1 H-NMR (tce-d) ⁇ : 7.30 (m, 2H), 4.70-4.30 (m, 4H). M n (SEC) approximately 20100 g/mol, PDI (SEC) 1.93.
  • 1,4-butanediol (122.3 g, 1.357 mol) and FDME (125 g, 0.678 mol) were polymerized in the same setup as used in A above using Tyzor®TPT as catalyst (84 ⁇ L).

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