US20220372664A1 - Textile fiber or web, methods and use related thereto - Google Patents

Textile fiber or web, methods and use related thereto Download PDF

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US20220372664A1
US20220372664A1 US17/771,194 US202017771194A US2022372664A1 US 20220372664 A1 US20220372664 A1 US 20220372664A1 US 202017771194 A US202017771194 A US 202017771194A US 2022372664 A1 US2022372664 A1 US 2022372664A1
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polymer
textile
binary
weight
polymer composition
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Martta Asikainen
Tommi Vuorinen
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Woodly Oy
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Woodly Oy
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    • 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
    • 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
    • D01D5/082—Melt spinning methods of mixed yarn
    • 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
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • 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
    • D01F2/24—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from cellulose derivatives
    • D01F2/28—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from cellulose derivatives from organic cellulose esters or ethers, e.g. cellulose acetate
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
    • D01F6/92—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyesters
    • 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
    • D04H1/425—Cellulose series
    • D04H1/4258—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
    • D04H1/40—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
    • D04H1/435—Polyesters
    • 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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/724—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged forming webs during fibre formation, e.g. flash-spinning
    • 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
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • 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
    • D04H3/013—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
    • 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
    • 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

Definitions

  • the present disclosure relates to synthetic textile fibers and to their manufacturing. Especially, to a textile fiber or textile web comprising a binary polymer composition.
  • Fibers are typically manufactured by various spinning methods. Such methods include wet spinning, dry spinning, melt spinning, extrusion spinning, direct spinning, gel spinning and electrospinning. Of these spinning methods, particularly interesting are the ones where no solvents are needed. Solvents in wet spinning for instance are often highly toxic. Melt spinning is one method where no solvents are needed but the polymer is extruded through the spinneret in molten stage and cooled. The polymer can be in different forms before the spinning process: granulate, fluff, fiber, or raw materials ready to be extruded directly into the spinning process.
  • Fibers can be further converted into yarn and fabric.
  • Textiles are produced for example by weaving and knitting yarn made of fibers.
  • Nonwovens are manufactured as sheets or webs of directionally of randomly oriented fibers, that have not been converted into yarns. These fibers can be bonded by for example adhesives, thermal methods, solvent treatments or stitching. The processes for producing nonwovens differ from those used for spun fibers. These methods include melt blowing, where the fibrous web or article is produced directly from the polymer of resin using high-velocity air. Spunbond nonwovens are made as continuous process where fibers are spun and then dispersed directly to a web. Nonwovens can also be produced from spun fibers, when the fibers are then cut and opened and laid into a web by a multistep process.
  • the invention concerns a textile fiber or textile web comprising a binary polymer composition, which comprises a first polymer being cellulose acetate propionate (CAP), and a second polymer being polybutylene succinate (PBS), and in which the total amount of the first and the second polymer is at least 80 weight-% of the binary polymer composition based on the total weight of the binary polymer compostions.
  • a binary polymer composition which comprises a first polymer being cellulose acetate propionate (CAP), and a second polymer being polybutylene succinate (PBS), and in which the total amount of the first and the second polymer is at least 80 weight-% of the binary polymer composition based on the total weight of the binary polymer compostions.
  • CAP cellulose acetate propionate
  • PBS polybutylene succinate
  • the invention also concerns a textile material comprising the textile fiber or textile web.
  • the invention concerns a method for manufacturing a textile fiber or a textile web from a binary polymer composition, which method comprises the following steps:
  • the invention also concerns use of a binary polymer composition
  • a binary polymer composition comprising a first polymer being cellulose acetate propionate (CAP), and a second polymer being polybutylene succinate (PBS), and wherein the total amount of the first and the second polymer is at least 80 weight-% based on the total weight of the binary polymer composition, in the manufacture of a textile fiber, a textile web, and/or a textile material.
  • CAP cellulose acetate propionate
  • PBS polybutylene succinate
  • FIG. 1 illustrates Example 1, Scanning electron microscopy of a binary polymer composition suitable for the invention, made of CAP 72.5% and PBS 27.5%.
  • FIG. 2 illustrates Example 4, fibers produced from a binary polymer composition according to this disclosure.
  • FIG. 3 illustrates Example 4, knitted fabric produced from the fibers of FIG. 2 .
  • Cellulose derivatives are used in textile fibers, but there are challenges regarding the used processes. Wet spinning and dry spinning processes require the use of toxic solvents. A melt spinning process requires the use of a large amounts of plasticizers and problems arise with the process temperatures. It is of high importance that the breaking elongation is good, and this is hard to obtain with fibers from cellulose derivatives.
  • the present invention provides a solution to these problems.
  • the present invention is based on the finding that new environmentally friendly good quality synthetic textile fibers and webs can be achieved by a binary polymer composition comprising cellulose acetate propionate (CAP) and a second polymer being polybutylene succinate (PBS).
  • CAP cellulose acetate propionate
  • PBS polybutylene succinate
  • the binary polymer composition comprises a further polymer selected from the group consisting of, polypropylene succinate (PPS), polybutylene succinate adipate (PBSA), polybutylene adipate terephthalate (PBAT), polylactic acid (PLA), polycaprolactone (PCL), polybutylene adipate (PBA), polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), polyethylene furanoate (PEF), polybutylene terephthalate (PBT), polybutylene succinate terephthalate (PBST), and any polyester containing sebacic and/or azelaic acid and/or dodecanedioic acid as dicarboxylic acid alone or in combination with terephthalic acid, and any combination of these.
  • PPS polypropylene succinate
  • PBSA polybutylene succinate adipate
  • PBAT polybutylene adipate terephthalate
  • PLA polylactic acid
  • PCL polycap
  • CAP and the second polymer, PBS form a homogeneous polymer mixture, i.e. there is no phase separation between the two polymers when the mixture is prepared with the method disclosed herein.
  • FIG. 1 showing a SEM (Scanning Electron Microscopy) picture of an embodiment of the invention (Example 1).
  • the binary polymer composition may provide a high quality raw-material for textile fiber and web production, with high tensile strength. Long textile fibers can be formed from strong fibers, and length of the fiber is important to provide good spinning results.
  • the textile fiber according to the invention is expected to have a diameter/bredth ratio of more than 100:1. Furthermore, it is expected that the strength, uniformity, spinnability and durability of the textile fibers according to the invention are good.
  • melt flow index (MFI) of the binary polymer blend is also applicable to fiber and nonwoven processes.
  • the material properties of the binary polymer compositions are similar to those of PET. Also, higher break elongation can be achieved. High break elongation is required for fiber applications and weaving processes.
  • the binary polymer composition used in textile fiber or web applications can also be a recycled feedstock.
  • the molecular weight and the length of molecular chains can be chosen to best meet the requirements of each fiber or nonwoven application.
  • the mechanical properties and processability can be modified by choosing longer or shorter polymer chains.
  • the textile fibers and webs comprise at least two polymers, a first polymer and a second polymer (a binary polymer composition).
  • the binary polymer composition comprises only two polymers, and optionally additives.
  • the textile fibers and webs according to this invention can be particulary suitable for replacing textile material made of PET (polyethylene terephthalate).
  • Syntetic PET fiber is widely used as the material in various fiber products.
  • the applications include industrial and consumer textiles.
  • the fibers and webs according to this invention may have high mechanical properties that are needed for high strength demanding application like ropes, nets and car textiles. These are typically made of polyester, and the fibers and webs according to the invention would be suitable for these application as an environmentally friendly high-quality alternative.
  • Many types of clothing are produced from polyesters as well as household and furnishing textiles including sheets, carpets and rugs, covers and curtains. Nonwovens, filters and sanitary products are also produced from polyesters.
  • the fibers and webs according to the invention could be suitable for all of the above applications.
  • PET has relatively high carbon footprint and these types of fibers, webs and textiles are not environmentally friendly. Typically, PET is mostly made from fossil resources. It is very difficult to make PET products more sustainable.
  • the present invention describes a new kind of textile fiber and web which may replace for example PET and PP in different types of fibers, yarns, textile and non-woven application.
  • PET materials were used as reference examples in tests performed in connection with the present invention (described in more detail in the Examples).
  • the fibers and webs made of binary polymer compositions presented herein have advantageous properties in tests performed in connection with the present invention.
  • the binary polymer composition provides good elongation properties. These are measured with tensile strain tests. In the tests they were compared to PET. Similar PET grades are used in the fiber production as plastic grade PET, this is one of the major recycled PET applications for plastic bottles and the like. It base been shown in tests performed in connection with the present invention that the binary polymer compositions for textile fiber or textile web applications may withstand recycling well.
  • the materials according to the invention based on binary polymer compositions presented herein can be processed with the same fiber and web production equipments as used with known material, such as PET fibers. This is beneficial, since no large investments in new equipment is needed.
  • the fibers and webs made from binary polymer compositions presented herein may have a low environmental impact. This has been shown in tests. Their global warming potential is much lower, and the renewable content is much higher than those of e.g. PET.
  • One aim of the invention is to achieve an environmentally friendly textile solution, which could replace traditional synthetic textile materilas based on fossil raw-materials.
  • biopolymers are preferred in the binary polymer composition.
  • Biopolymers are polymers which are made, either partially or completely, from renewable resources. Another definition of biopolymers are polymers which are biodegradable. It is enough for a biopolymer to fulfil one of these definitions.
  • the invention concerns a textile fiber or textile web comprising a binary polymer composition, which comprises a first polymer being cellulose acetate propionate (CAP), and a second polymer being polybutylene succinate (PBS).
  • CAP cellulose acetate propionate
  • PBS polybutylene succinate
  • the binary polymer composition comprises a further polymer selected from the group consisting of polypropylene succinate (PPS), polybutylene succinate adipate (PBSA), polybutylene adipate terephthalate (PBAT), polylactic acid (PLA), polycaprolactone (PCL), polybutylene adipate (PBA), polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), polyethylene furanoate (PEF), polybutylene terephthalate (PBT), polybutylene succinate terephthalate (PBST), and any polyester containing sebacic and/or azelaic acid and/or dodecanedioic acid as dicarboxylic acid alone or in combination with terephthalic acid, and any combination of these.
  • PPS polypropylene succinate
  • PBSA polybutylene succinate adipate
  • PBAT polybutylene adipate terephthalate
  • PLA polylactic acid
  • PCL polycaprol
  • the binary polymer composition comprises the first polymer in an amount of 5 to 95 weight-%, and the second polymer in an amount of 95 to 5 weight-%, based on the total weight of the binary polymer composition.
  • the total amount of the first polymer and said second polymer it at least 80 wt. %, or at least 85 wt. %.
  • the amount is at least 90 wt. %, or at least 95 wt. %, based on the total weight of the binary polymer composition the rest being other polymers and/or additives such as softeners, pigments, stabilizers or other additives for use in plastic compositions.
  • the binary polymer composition comprises the first polymer in an amount of 55 to 80 weight-%, or 60 to 75 weight-%, or 65 to 75 weight-%, and the second polymer in an amount of 20 to 45 weigh-%, or 25 to 40 weight-%, or 25 to 35 weight-%.
  • the binary polymer composition comprises recycled binary polymer composition comprising cellulose acetate propionate (CAP) and polybutylene succinate (PBS).
  • CAP cellulose acetate propionate
  • PBS polybutylene succinate
  • the invention also concerns a textile material comprising the textile fiber or textile web according to any embodiment described herein.
  • the textile material is selected from the group consisting of a fiber, a yarn, textiles, fabrics, nonwovens, textile products for one of the following applications; apparel, household, industrial, technical, ropes, nets and car textiles, household and furnishing textiles including sheets, carpets and rugs, covers and curtains, and nonwovens, such as filters and sanitary products.
  • the textile material is recyclable.
  • the invention relates to a method for manufacturing a textile fiber or a textile web from a binary polymer composition.
  • the method of the invention comprises the following steps:
  • the binary polymer composition comprises a further polymer selected from the group consisting of polypropylene succinate (PPS), polybutylene succinate adipate (PBSA), polybutylene adipate terephthalate (PBAT), polylactic acid (PLA), polycaprolactone (PCL), polybutylene adipate (PBA), polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), polyethylene furanoate (PEF), polybutylene terephthalate (PBT), polybutylene succinate terephthalate (PBST), and any polyester containing sebacic and/or azelaic acid and/or dodecanedioic acid as dicarboxylic acid alone or in combination with terephthalic acid, and any combination of these.
  • PPS polypropylene succinate
  • PBSA polybutylene succinate adipate
  • PBAT polybutylene adipate terephthalate
  • PLA polylactic acid
  • PCL polycaprol
  • obtaining a homogenous polymer blend is not performed in a separate step, but rather in the same step as forming the blend into a textile fiber or textile web.
  • the method of forming the homogenous polymer blend into a textile fiber is done by a spinning method selected from the group consisting of wet spinning, dry spinning, melt spinning, extrusion spinning, direct spinning, gel spinning and electrospinning.
  • a spinning method selected from the group consisting of wet spinning, dry spinning, melt spinning, extrusion spinning, direct spinning, gel spinning and electrospinning.
  • melt spinning and/or direct spinning are used.
  • forming the homogenous polymer blend into a textile fiber is done by a melt spinning method, where the melt spinning temperature is between 180 and 270° C.
  • the temperature may also be between 200 and 250° C., or between 210 and 230° C., or between 215 and 225° C.
  • forming the homogenous polymer blend into a textile fiber is done by a melt spinning method using a melt spinneret with at least one hole with a hole diameter of 0.1 to 2 mm, or 0.5 to 1.5 mm, or 0.8 to 1.2 mm.
  • the diameter may also be about 1 mm.
  • the suitable diameter of the spinneret depends on the desired quality of the fiber.
  • the spinneret can typically have any number of holes between 1 and 1000, such as 2 to 500 holes, or 5 to 50 holes.
  • forming said homogenous polymer blend into a textile web is done by melt blow and/or spunbond.
  • obtaining the homogenous polymer blend is performed by melt-mixing.
  • the melt-mixing is performed at a temperature between 200° C. and 300° C.
  • the temperature is between 200° C. and 270° C., or between 210° C. and 250° C., or between 210° C. and 230° C.
  • obtaining a homogenous polymer blend is done by a recycling process.
  • the method may be used to obtain a textile fiber or a textile web based on a binary polymer composition according to any one of the embodiments described herein.
  • the invention also concerns use of a binary polymer composition
  • a binary polymer composition comprising a first polymer being cellulose acetate propionate (CAP), and a second polymer being polybutylene succinate (PBS), and wherein the total amount of said first and said second polymer is at least 80 weight-% based on the total weight of said binary polymer compostions, in the manufacture of a textile fiber, a textile web, and/or a textile material.
  • CAP cellulose acetate propionate
  • PBS polybutylene succinate
  • the binary polymer composition comprises a further polymer selected from the group consisting of polypropylene succinate (PPS), polybutylene succinate adipate (PBSA), polybutylene adipate terephthalate (PBAT), polylactic acid (PLA), polycaprolactone (PCL), polybutylene adipate (PBA), polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), polyethylene furanoate (PEF), polybutylene terephthalate (PBT), polybutylene succinate terephthalate (PBST), and any polyester containing sebacic and/or azelaic acid and/or dodecanedioic acid as dicarboxylic acid alone or in combination with terephthalic acid, and any combination of these.
  • PPS polypropylene succinate
  • PBSA polybutylene succinate adipate
  • PBAT polybutylene adipate terephthalate
  • PLA polylactic acid
  • PCL polycaprol
  • the binary polymer composition comprises CAP in an amount of 5 to 95 weight-%, preferably 10 to 90 weight-%, more preferably 20 to 80 weight-%, and the second polymer in an amount of 5 to 95 weight-%, preferably 10 to 90 weight-%, more preferably 20 to 80 weight-%, based on the total weight of the polymer composition.
  • PBS is used, and the PBS has a number average molar mass in the range of 30,000 to 100,000 Da. Typically, 50,000 to 80,000 Da, or for example 60,000 to 70,000 Da.
  • the binary polymer composition comprises CAP in an amount of 55 to 80 weight-%. Typically, in an amount of 60 to 75 weight-%, or 65 to 75 weight-%.
  • the composition then comprises the second polymer in an amount of 20 to 40 weight-%. Typically, 25 to 40 weight-%, or 25 to 35 weight-%.
  • Weight-%:s are based on the total weight of the composition.
  • the mixture comprises at least one additive such as softeners, pigments, stabilizers and/or other additives for use in plastic compositions.
  • the binary polymer composition consists of CAP in an amount of 60 to 80 weight-%, typically 60 to 75 weight-%, or 65 to 75 weight-%, and PBS in an amount of 20 to 40 weight-%, typically 25 to 40 weight-% or 25 to 35 weight %, based on the total weight of the composition, and optionally at least one additive, such as softeners, pigments, dyes, stabilizers and/or other additives for use in plastic compositions, and/or other thermoplastic polymers compatible with CAP and PBS.
  • CAP in an amount of 60 to 80 weight-%, typically 60 to 75 weight-%, or 65 to 75 weight-%
  • PBS in an amount of 20 to 40 weight-%, typically 25 to 40 weight-% or 25 to 35 weight %, based on the total weight of the composition
  • at least one additive such as softeners, pigments, dyes, stabilizers and/or other additives for use in plastic compositions, and/or other thermoplastic polymers compatible with CAP and PBS.
  • the binary polymer composition comprises at least one softener.
  • TEC triethyl citrate
  • the CAP has a number average molar mass of 15,000 to 120,000 Da, or 30,000 to 110,000 Da. Typically, 50,000 to 100,000 Da; or for example 65,000 to 95,000 Da.
  • CAP has an acetyl content of 0.8 to 2.0 wt. %, or 1.0 to 1.5 wt. %, and/or a propionyl content of 30 to 51 wt. %, or 40 to 50 wt. %, and/or a hydroxyl content of 1.0 to 2.5 wt. %, or 1.5 to 2.0 wt. %.
  • the number average molar mass of the CAP polymer is above 20,000 Da.
  • the number average molar mass is between 30,000 to 110,000 Da, typically between 50,000 to 100,000 Da, or 65,000 to 95,000 Da.
  • the number average molar mass may be between 85,000 and 95,000 Da, or between 85,000 and 91,000 Da, for example 90,000 Da, 91,000 Da or 92,000 Da.
  • a number average molar mass within the above defined ranges may provide a resilient material with mechanical properties that withstand processing and form durable textile fibers.
  • All number average molar mass measurements performed in connection with the invention were measured with size exclusion chromatography (SEC) using chloroform eluent for the number average molar mass measurements.
  • SEC size exclusion chromatography
  • the elution curves were detected using Waters 2414 Refractive index detector.
  • the molar mass distributions (MMD) were calculated against 10 ⁇ PS (580-3040000 g/mol) standards, using Waters Empower 3 software.
  • the polymer raw materials affect the properties of the formed mixture.
  • the combined properties of the polymers need to be evaluated when forming the composition according to the invention.
  • one of the polymers has a high number average molar mass, such as 90,000 Da or 70,000 Da, it could be suitable to combine this polymer with another polymer having a lower number average molar mass.
  • a higher amount of softener may be used together with polymers with a high molar mass.
  • the suitable number average molar mass depends on the end use of the composition, i.e.
  • the CAP suitable for the composition of the present invention suitably has an acetyl content of 0.8 to 2.0 wt. %. Typically, 1.0 to 1.5 wt. %, for example 1.3 wt. %.
  • the CAP suitable for the composition of the present invention suitably has a propionyl content of 30 to 51 wt. %. Typically, it may be 40 to 50 wt. %. A very specific example is 48 wt. %.
  • the CAP suitable for the composition of the present invention suitably has hydroxyl content of 1.0 to 2.5 wt. %. Typically, 1.5 to 2.0 wt. %, for example 1.7 wt. %.
  • the glass transition temperature is suitably 140 to 155° C. Typically, 142 to 152° C., for example 147° C.
  • the PBS suitable for the composition of the present invention has a number average molar mass in the range of 30,000 to 100,000 Da. Typically, 50,000 to 80,000 Da; or 60,000 to 70,000 Da.
  • the number average molar mass of the PBS may be for example 65,000 to 70,000 Da, such as for example 68,000 Da, 69,000 Da or 70,000 Da.
  • Melt flow index is a measure to describe ease of flow of the melt of a thermoplastic polymer or plastic.
  • the melt flow index can be used to characterize a polymer or a polymer mixture.
  • polyolefins i.e. polyethylene (PE, at 190° C.) and polypropylene (PP, at 230° C.
  • the MFI is commonly used to indicate order of magnitude for its melt viscosity.
  • PP polypropylene
  • MFI is inversely proportional to molecular weight.
  • the MFI was measured at two temperatures 215 and 240° C.
  • the binary polymer composition has a melt flow index of 6 to 8 g/10 min. Suitably, about 7 g/10 min, or 6.9 g/10 min. Measured at: load 2.16 kg, at 215° C., and/or about 26 to 28 g/10 min, 27 g/10 min, or 27.1 g/10 min, load 2.16 kg, at 240° C.
  • the binary polymer composition suitable for the solution according to the invention comprises CAP and the second polymer, for example PBS, in combination with another component, which is selected from the list consisting of a cellulose ester, such as cellulose acetate or cellulose acetate butyrate (CAB), and polybutylene succinate (PBS), polypropylene succinate (PPS), polybutylene succinate adipate (PBSA), polybutylene adipate terephthalate (PBAT), polylactic acid (PLA), polycaprolactone (PCL), polybutylene adipate (PBA), polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), polyethylene furanoate (PEF), polybutylene terephthalate (PBT), polybutylene succinate terephthalate (PBST), and any polyester containing sebacic and/or azelaic acid and/or dodecanedioic acid as dicarboxylic acid alone or in combination with tere
  • the elongation and other mechanical properties of the binary polymer compositions can also be modified with small amounts of additives to reach the elongation and other properties required.
  • thee binary polymer composition may also comprise other components, such as additives typically used in textile fibers or textile webs. These additives are for example softeners or plasticizers, fillers, aids, pigments, stabilizers or other agents.
  • additives typically used in textile fibers or textile webs.
  • these additives are for example softeners or plasticizers, fillers, aids, pigments, stabilizers or other agents.
  • the amounts of these additives vary between 0.01 to 10 weight-% based on the weight of the binary polymer composition used in the invention.
  • the amount of one additive may for example be 0.1 to 5 weight-% based on the total weight of the composition.
  • the solution according to the present invention has several advantages. The most important are:
  • FIG. 1 illustrates Example 1, Scanning electron microscopy of a binary polymer composition suitable for the invention, made of CAP 72.5% and PBS 27.5%.
  • FIG. 2 illustrates fibers produced from the binary polymer composition.
  • FIG. 3 illustrates knitted fabric produced from the fibers of FIG. 2 .
  • Homogeneous mixtures of a binary polymer composition were formed into granulate and films. Homogeneous polymer mixtures were obtained by melt mixing. The mixing was conducted at temperatures between 210-230° C. for a time period of 30 sec to 4 min.
  • the binary polymer blend consisting of 72.5% CAP and 27.5% of PBS was made into a film.
  • the film was treated with liquid nitrogen.
  • the samples were broken under liquid nitrogen to give perfect cross-section view into the film.
  • the SEM cross-section views did not show any fine structure and is homogeneous showing excellent miscibility of the polymer blend ( FIG. 1 ).
  • the breaking elongation of the material is also called tensile strain. This can be measured for yield and for break.
  • the elongation at break for the binary polymer blend is measured to be up to 97%.
  • the MFI (melt flow index) of the binary polymer blends is suitable for fiber production at different temperatures.
  • melt-spund fiber could be manufactured.
  • a ready compounded binary polymer could be used and fed to the spinning process.
  • feeding the CAP and PBS polymers separately directly into the spinning process could be done.
  • the products based on a melt-spun process are fibres, from which different fiber and yarn products can be made.
  • the yarn can also be woven or knitted into textiles and fabrics for various applications.
  • a binary polymer composition comprising CAP and PBS can be processed into nonwovens with the at least the following methods; melt blown process and a spunbond process.
  • a ready compounded binary polymer could be used and fed to the web forming process. Alternatively, feeding the CAP and PBS polymers separately directly into the process.
  • the products and finished articles from a melt blown process and a spunbond process are nonwoven textiles.
  • melt spinning was carried out with a Fourne melt spinning machine (Fourne Polymertechnik GmbH, Germany).
  • the melt spinning line consisted of a 10 mm single screw extruder, metering pump, and melt spinneret with 8 holes (diameter 1 mm).
  • the spinning temperature was set to 215° C.
  • the as-spun fibers were guided through a quench duct with ambient temperature.
  • the melt spun fibers were collected on skein as spun. No orientation forces were applied in the fibers.
  • This recycled granulate was made into a fiber product with a melt spinning machine.
  • melt spinning was carried out with a Fourne melt spinning machine (Fourne Polymertechnik GmbH, Germany).
  • the melt spinning line consisted of a 10 mm single screw extruder, metering pump, and melt spinneret with 8 holes (diameter 1 mm).
  • the spinning temperature was set to 215° C.
  • the as-spun fibers were guided through a quench duct with ambient temperature.
  • the melt spun fibers were collected on skein as spun. No orientation forces were applied in the fibers.
  • the recycled blend was easy to process with the spinning machine and the fibers were easily collected with no breakages indicating good recyclability for the blends.
  • a product, a system, a method, or a use, disclosed herein may comprise at least one of the embodiments described hereinbefore.
  • the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.
  • the embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.
  • reference to ‘an’ item refers to one or more of those items.
  • the term “comprising” is used in this specification to mean including the feature(s) or act(s) followed thereafter, without excluding the presence of one or more additional features or acts.

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  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Artificial Filaments (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
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US20150368442A1 (en) * 2013-01-30 2015-12-24 Nec Corporation Cellulose resin composition, molding material and molded article
WO2019160906A1 (en) * 2018-02-13 2019-08-22 Eastman Chemical Company Cellulose ester and polymeric aliphatic polyester compositions and articles
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CN107794597B (zh) * 2016-09-06 2020-12-01 中国石油化工股份有限公司 热塑性纤维素与脂肪族共聚酯共混物纤维及制备方法

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US20150368442A1 (en) * 2013-01-30 2015-12-24 Nec Corporation Cellulose resin composition, molding material and molded article
US20190256674A1 (en) * 2016-07-22 2019-08-22 Eastman Chemical Company Cellulose ester compositions for calendering
WO2019160906A1 (en) * 2018-02-13 2019-08-22 Eastman Chemical Company Cellulose ester and polymeric aliphatic polyester compositions and articles

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