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
  • 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
  • D01F8/12—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyamide as constituent
• • 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
  • D01D4/00—Spinnerette packs; Cleaning thereof
  • D01D4/02—Spinnerettes
• • 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
  • 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
  • D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
  • D06M23/12—Processes in which the treating agent is incorporated in microcapsules
• • 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
  • Y10T428/2933—Coated or with bond, impregnation or core

Definitions

• the present invention relates to the field of particulate-loaded polymer fibers along with extrusion processing and apparatus for manufacturing the same.
• the conventional strategy in extruding molten polymer for fiber making is to reduce the molecular weight of the polymeric material to attain economically viable processing rates.
• the reduced molecular weight results in a corresponding compromise in material properties of the extruded polymeric fibers.
• the fiber strength may be improved by orienting the polymeric material in the fiber. Orientation is imparted by pulling or stretching the fiber after it exits the extrusion die.
• the polymeric material used for the fibers typically must have a substantial tensile stress carrying capability in the semi- molten state in which the polymeric material exits the die (or the fibers will merely break when pulled).
• Such properties are conventionally available in semi-crystalline polymers such as, e.g., polyethylene, polypropylene, polyesters, and polyamides.
• conventional fiber extrusion processes can be performed with only a limited number of polymeric materials.
• the present invention provides particulate-loaded polymer fibers along with methods and systems for extruding polymeric fibers.
• the particulate-loaded polymer fibers have a fiber body that includes a polymeric binder with a plurality of particles distributed within the polymeric binder. Some of the particles are completely encapsulated within the polymeric binder and others may be partially exposed on the outer surface of the fiber body.
• the polymeric fiber body can be formed of polymers with relatively low melt flow index or relatively high melt viscosity (and corresponding high molecular weight as discussed herein).
• the potential benefits associated with fibers manufactured using such polymers in methods of the present invention may also be available for particulate-loaded fibers.
• the particles within the fiber body may preferably be distributed such that the particle density (i.e., the number of particles per unit volume of the fiber body) is higher proximate the outer surface of the fiber. That distribution of particles within the fiber may be advantageous for enhancing fiber strength (by, e.g., providing a central core that includes fewer particles).
• the particle distribution profile may also be advantageous in situations where it is desired that the particles be encapsulated near the outer surface of the fiber or partially exposed on the outer surface of the fiber. This may be particularly true in situations in which it is beneficial if additional particles are exposed as portions of the polymeric binder are removed during use (as may happen in, e.g., fibers used in abrasive articles, etc.).
• Another potential advantage of the particle distribution seen in melt-extruded fibers of the present invention is that the amount of particles needed to provide a selected particle density proximate the outer surface of the fiber may be reduced because the particles are preferentially distributed proximate the outer surface of the fiber.
• the extrusion process used to manufacture the fibers may preferably involve the delivery of a lubricant separately from a polymer melt stream to each orifice of an extrusion die such that the lubricant preferably encases the polymer melt stream as it passes through the die orifice.
• a lubricant delivered separately from the polymer melt stream in a polymeric fiber extrusion process can provide a number of potential advantages.
• the use of separately-delivered lubricant can provide for oriented polymeric fibers in the absence of pulling, i.e., in some embodiments it may not be necessary to pull or stretch the fiber after it exits the die to obtain an oriented polymeric fiber. If the polymeric fibers are not pulled after extrusion, they need not exhibit substantial tensile stress-carrying capability in the semi-molten state that they are in after exiting the die. Instead, the lubricated extrusion methods of the present invention can, in some instances, impart orientation to the polymeric material as it moves through the die such that the polymeric material may preferably be oriented before it exits the die.
• One potential advantage of reducing or eliminating the need for pulling or stretching to impart orientation is that the candidate polymeric materials for extruding polymeric fibers can be significantly broadened to include polymeric materials that might not otherwise be used for extruded fibers. Heterophase polymers may also be extruded into an oriented fiber via the proposed method.
• Composite fiber constructions such as
• the term "fiber” means a slender, threadlike structure or filament that has a substantially continuous length relative to its width, e.g., a length that is at least 1000 times its width.
• the width of the fibers of the present invention may preferably be limited to a maximum dimension of 5 millimeters or less, preferably 2 millimeters or less, and even more preferably 1 millimeter or less.
• the fibers of the present invention may be monocomponent fibers; bicomponent or conjugate fibers (for convenience, the term "bicomponent” will often be used to mean fibers that consist of two components as well as fibers that consist of more than two components); and fiber sections of bicomponent fibers, i.e., sections occupying part of the cross-section of and extending over the length of the bicomponent fibers.
• MFI Melt Flow Index
• the MFI of the extruded polymers is about 35 or higher.
• the extrusion of polymeric fibers can be achieved using polymers with a MFI of 30 or less, in some instances 10 or less, in other instances 1 or less, and in still other instances 0.1 or less.
• extrusion processing of such high molecular weight (low MFI) polymers to form fibers was typically performed with the use of solvents to dissolve the polymers thereby reducing their viscosity.
• low melt flow index polymers examples include LURAN S 757 (ASA, 8.0 MFI) available from BASF Corporation of Wyandotte, MI; P4G2Z-026 (PP, 1.0 MFI) available from Huntsman Polymers of Houston, TX; FR PE 152 (HDPE, 0.1 MFI) available from PolyOne Corporation of Avon Lake, OH; 7960.13 (HDPE, 0.06 MFI) available from ExxonMobil Chemical of Houston TX; and ENGAGE 8100 (ULDPE, 1.0 MFI) available from ExxonMobil Chemical of Houston TX.
• ASA 8.0 MFI
• PP 1.0 MFI
• Another potential advantage of some methods of the present invention may include the relatively high mass flow rates that may be achieved. For example, using the methods of the present invention, it may be possible to extrude polymeric material into fibers at rates of 10 grams per minute or higher, in some instances 100 grams per minute or higher, and in other instances at rates of 400 grams per minute or higher. These mass flow rates may be achieved through an orifice having an area of 0. 2 square millimeters (mm 2 ) or less.
• Still another potential advantage of some methods of the present invention may include the ability to extrude polymeric fibers that include orientation at the molecular level that may, e.g., enhance the strength or provide other advantageous mechanical, optical, etc. properties.
• the amorphous polymeric fibers may optionally be characterized as including portions of rigid or ordered amorphous polymer phases or oriented amorphous polymer phases (i.e., portions in which molecular chains within the fiber are aligned, to varying degrees, generally along the fiber axis).
• oriented polymeric fibers are known, the orientation is conventionally achieved by pulling or drawing the fibers as they exit a die orifice. Many polymers cannot, however, be pulled after extrusion because they do not possess sufficient mechanical strength immediately after extrusion in the molten or semi-molten state to be pulled without breaking.
• the methods of the present invention can, however, eliminate the need to draw polymeric fibers to achieve orientation because the polymeric material may be oriented within the die before it exits the orifice. As a result, oriented fibers may be extruded using polymers that could not conventionally be extruded and drawn in a commercially viable process.
• the lubricant may be selected based, at least in part, on its ability to quench the polymeric material by, e.g., evaporation.
• the present invention provides a particulate-loaded polymeric fiber having a fiber body that includes a polymeric binder and a plurality of particles encapsulated within the polymeric binder, wherein the polymeric binder consists essentially of one or more polymers, and wherein the encapsulated particles have an encapsulated particle density, and wherein the encapsulated particle density is higher proximate an outer surface of the fiber.
• the present invention provides a particulate-loaded polymeric fiber having a fiber body that includes one or more polymers, and wherein all of the one or more polymers have a melt flow index of 10 or less measured at the conditions specified for the one or more polymers; and a first plurality of particles encapsulated within the fiber body and a second plurality of particles embedded in an outer surface of the fiber body, wherein the encapsulated first plurality of particles have an encapsulated particle density, and wherein the encapsulated particle density of the first plurality of particles is highest proximate an outer surface of the fiber.
• the present invention provides a method of making a particulate - loaded polymeric fiber by entraining a plurality of particles within a polymer melt stream; passing the polymer melt stream with the plurality of particles entrained therein through an orifice located within a die, wherein the orifice has an entrance, an exit and an interior surface extending from the entrance to the exit, wherein the orifice is a semi-hyperbolic converging orifice, and wherein the polymer melt stream enters the orifice at the entrance and leaves the orifice at the exit; delivering lubricant to the orifice separately from the polymer melt stream, wherein the lubricant is introduced at the entrance of the orifice; and collecting the particulate-loaded polymeric fiber including the polymer melt stream and a plurality of particles encapsulated within the polymer melt stream, wherein the encapsulated particles comprise an encapsulated particle density within the fiber, and wherein the encapsulated particle density is higher proximate an outer surface
• the present invention may provide a method of making a polymeric fiber by passing a polymer melt stream through an orifice located within a die, wherein the orifice has an entrance, an exit and an interior surface extending from the entrance to the exit, wherein the orifice is a semi-hyperbolic converging orifice, and wherein the polymer melt stream enters the orifice at the entrance and leaves the orifice at the exit; delivering lubricant to the orifice separately from the polymer melt stream, wherein the lubricant is introduced at the entrance of the orifice; and collecting a fiber including the polymer melt stream after the polymer melt stream leaves the exit of the orifice.
• the present invention may provide a method of making a polymeric fiber by passing a polymer melt stream through an orifice of a die, wherein the orifice has an entrance, an exit and an interior surface extending from the entrance to the exit, wherein the orifice is a semi-hyperbolic converging orifice, wherein the polymer melt stream enters the orifice at the entrance and leaves the orifice at the exit, wherein the polymer melt stream includes a bulk polymer, wherein the bulk polymer is a majority of the polymer melt stream, and wherein the bulk polymer consists essentially of a polymer with a melt flow index of 1 or less measured at the conditions specified for the polymer in ASTM D1238; delivering lubricant to the orifice separately from the polymer melt stream; and collecting a fiber including the bulk polymer after the polymer melt stream leaves the exit of the orifice.
• FIG. 1 is an idealized enlarged cross-sectional view of one particulate-loaded fiber according to the present invention.
• FIG. 2 is a schematic diagram illustrating a process window for methods according to the present invention.
• FIG. 3 is an enlarged cross-sectional view of a portion of one exemplary die that may be used in connection with the present invention.
• FIG. 4 is an enlarged view of the orifice in the die of FIG. 3.
• FIG. 5 is a plan view of a portion of one exemplary extrusion die plate that may be used in connection with the present invention.
• FIG. 6 is a schematic diagram of one system including a die according to the present invention.
• FIG. 7 is an enlarged cross-sectional view of another extrusion apparatus that may be used in connection with the present invention.
• FIG. 8 is an enlarged plan view of another exemplary die orifice and lubrication channels that may be used in connection with the present invention.
• FIG. 9 is an enlarged cross-sectional view of one exemplary polymeric fiber exiting a die orifice in accordance with the methods of the present invention.
• the present invention provides methods and systems for manufacturing polymeric fibers through a lubricated flow extrusion process.
• the present invention also provides particulate-loaded polymeric fibers that may preferably be manufactured using such systems and methods.
• FIG. 1 is an idealized cross-sectional view of one exemplary particulate-loaded fiber 2 in accordance with the present invention.
• the fiber 2 is formed with a longitudinal axis 3 extending along its length.
• the fiber 2 includes a body 4 formed of one or more polymers (sometimes referred to herein as a polymeric binder).
• the body 4 extends along the length of the longitudinal axis 3 and includes an outer surface 5.
• the fiber body 4 depicted in FIG. 1 has a generally circular cross-section shape (taken transverse to the longitudinal axis 3), the fibers of the present invention may take any suitable cross- sectional shape, e.g., oval, triangular, rectangular, hexagonal, irregular, etc.
• the one or more polymers used to form the fiber body 4 may have any composition as described herein.
• the one or more polymers of fiber body 4 may have a melt flow index (MFI) 30 or less, 10 or less, 1 or less, 0.1 or less, etc.; it may be preferred that the one or more polymers be semi-crystalline polymers (e.g., nylon); etc.
• MFI melt flow index
• particles 6 which are encapsulated (where "encapsulated” means that that particles are completely contained within the polymer forming the fiber body 4.
• the fiber 2 may also includes particles 7 that are only embedded (or partially encapsulated) in the polymer forming the fiber body 4 such that a portion of the particle is exposed on the outer surface 5 of the fiber body 4.
• the encapsulated particles 6 are distributed within the fiber such that the encapsulated particle density is higher proximate the outer surface 5 of the fiber 2.
• encapsulate particle density refers to the number of encapsulated particles per unit volume of the fiber. In some embodiments, it may be preferred that the encapsulated particle density within the outermost 20% of the volume of the fiber be two times or more the particle density within the innermost 20% of the volume of the fiber. Alternatively, it may be preferred that 50% or more of the encapsulated particles be located within the outermost 20% of the fiber. In another alternative, it may be preferred that 90% of the encapsulated particles be located within the outermost 10% of the volume of the fiber.
• the particles 6 may preferably be formed of materials that do not readily intermix with or melt into the polymeric body 4. It may be preferred that the particles 6 & 7 be formed of non-polymeric materials (although it should be understood that some particles may be used in connection with the present invention if their melt processing temperatures (as defined herein) are high enough such that the particles 6 & 7 retain their separate and distinct form from the surrounding fiber body 4).
• non-polymeric particles may include, e.g., metals, metal oxides (e.g., aluminum oxide), ceramics, glasses, minerals, etc.
• the particles added to fibers of the present invention may include optical functionality as, e.g., retroreflectors, etc.
• optical functionality e.g., retroreflectors, etc.
• examples of some potentially suitable optical elements that may be used as particles in connection with the present invention may be described in, e.g., U.S. Patent Nos. 4,367,919 (Tung et al.); 5,774,265 ( Mathers et al.); 5,835,271 (Stump et al.); 5,853,851 (Morris), etc.
• the particles used in connection with the particulate-loaded fibers of the present invention may potentially be characterized on the basis of their size. It may be preferred, for example, that the particles be small enough such that they do not inhibit fiber formation or extrusion (if that is the process by which the fibers are formed). In some instances, it may be preferred that the particles have a maximum dimension of 1 millimeter or less, 500 micrometers or less, 250 micrometers or less, 100 micrometers or less, 50 micrometers or less, or 10 micrometers or less. As used herein, "maximum size" of particles is determined by screening or sieving such that the particles pass through a screen or sieve with openings of the particle size or larger.
• the maximum size may be described as a function of the fiber diameter.
• the maximum size of the particles in a particulate-loaded fiber of the present invention be 10% or less of the fiber diameter, 30% or less of the fiber diameter, or 50% or less of the fiber diameter.
• the particulate-loaded fibers of the present invention may preferably be manufactured by methods that involve the extrusion of a polymer melt stream from a die having one or more orifices.
• the particles to be encapsulated within the body of the fiber are preferably entrained within the polymer melt stream as it is delivered to the die.
• a lubricant is delivered to the die separately from the polymer melt stream, preferably in a manner that results in the lubricant being preferentially located about the outer surface of the polymer melt stream as it passes through the die.
• the lubricant may be another polymer or another material such as, e.g., mineral oil, etc.
• the viscosity of the lubricant be substantially less than the viscosity of the lubricated polymer (under the conditions at which the lubricated polymer is extruded).
• FIG. 2 depicts a dimensionless graph to illustrate this potential advantage.
• the flow rate of the polymer melt stream increases moving to the right along the x-axis and the flow rate of the lubricant increases moving upward along the y-axis.
• the area between the broken line (depicted nearest the x-axis) and the solid line (located above the broken line) is indicative of area in which the flow rates of the polymer melt stream and the lubricant can be maintained at a steady state with respect to each other.
• Characteristics of steady state flow are preferably steady pressures for both the polymer melt stream and the lubricant.
• steady state flow may also preferably occur at relatively low pressures for the lubricant and/or the polymer melt stream.
• the area above the solid line is indicative of the region in which an excess of lubricant may cause flow of the polymer melt stream through the die to pulse.
• the pulsation can be strong enough to interrupt the polymer melt stream flow and break or terminate any fibers exiting the die.
• the area below the broken line is indicative of the conditions at which the lubricant flow stalls or moves to zero.
• the flow of the polymer melt stream is no longer lubricated and the pressure of the polymer melt stream and the lubricant typically rise rapidly.
• the pressure of the polymer melt stream can rise from 200 psi (1.3 x 10 6 Pa) to 2400 psi (1.4 x 10 7 Pa) in a matter of seconds under such conditions.
• This area would be considered the conventional operating window for traditional non-lubricated fiber forming dies, with the mass flow rate of the polymers being limited principally by the high operating pressures.
• the widened process window illustrated in FIG. 2 may preferably be provided using a die in which the orifices converge in a manner that results in essentially pure elongational flow of the polymer. To do so, it may be preferred that the die orifice have a semi-hyperbolic converging profile along its length (i.e., the direction in which the first polymer flows) as discussed herein.
• melt flow index is a common industry term related to the melt viscosity of a polymer.
• ASTM American Society for Testing and Materials
• ASTM D1238 This test method specifies loads and temperatures that are to be used to measure specific polymer types.
• melt flow index values are to be obtained at the conditions specified by ASTM D 1238 for the given polymer type.
• the general principle of melt index testing involves heating the polymer to be tested in a cylinder with a plunger on top and a small capillary or orifice located at the bottom of the cylinder.
• melt index value is typically associated with a higher flow rate and lower viscosity, both of which may be indicative of a lower molecular weight.
• low melt index values are typically associated with lower flow rates and higher viscosities, both of which may be indicative of a higher molecular weight polymer.
• the MFI of the extruded polymers is about 35 or higher.
• the polymer melt stream used to form the extruded polymeric fibers may include one or more polymers, with all of the one or more polymers exhibiting a MFI of 30 or less, in some instances 10 or less, in other instances 1 or less, and in still other instances 0.1 or less.
• the polymer melt stream may consist essentially of one polymer that preferably exhibits a MFI of 30 or less, in some instances 10 or less, in other instances 1 or less, and in still other instances 0.1 or less.
• the polymer melt stream may be characterized as including a bulk polymer that forms at least a majority of the volume of the polymer melt stream. In some instances, it may be preferred that the bulk polymer form 60% or more of the volume of the polymer melt stream, or in other instances, it may be preferred that the bulk polymer form 75% or more of the volume of the polymer melt stream. In these instances, the volumes are determined as the polymer melt stream is delivered to the orifice of a die.
• the bulk polymer may preferably exhibit a MFI of 30 or less, in some instances 10 or less, in other instances 1 or less, and in still other instances 0.1 or less.
• the polymer melt stream may include one or more secondary polymers in addition to the bulk polymer.
• the secondary polymers may preferably exhibit a MFI of 30 or less, in some instances 10 or less, in other instances 1 or less, and in still other instances 0.1 or less.
• UHMWPE Ultra High Molecular Weight polyethylene
• EPDM Ethylene-Propylene-Diene-Monomer
• EAA Ethylene-Propylene-Diene-Monomer
• EMMA Metallocene copolymers
• polyphenylene sulfide polyphenylene sulfide
• low MFI polymers that may be compatible with the present invention are the traditional "glassy” polymers.
• glassy used here is the same traditional use of a dense random morphology that displays a glass transition temperature (T g ), characteristic of density, rheology, optical, and dielectric changes in the material.
• glassy polymers may include, but are not limited to: polymethylmethacrylates, polystyrenes, polycarbonates, polyvinylchlorides, etc.
• low MFI polymers that may be compatible with the present invention are the traditional "rubbery” polymers.
• rubbery is the same as used in traditional nomenclature: a random macromolecular material with sufficient molecular weight to form significant entanglement so as to result in a material with a long relaxation time.
• rubbery polymers may include, but are not limited to; polyurethanes, ultra low density polyethylenes, styrenic block copolymers such as styrene-isoprene- styrene (SIS), styrene-butadiene-styrene (SBS) styrene-ethylene/butylene-styrene (SEBS), polyisoprenes, polybutadienes, EPDM rubber, and their analogues.
• SIS styrene-isoprene- styrene
• SBS styrene-butadiene-styrene
• SEBS styrene-ethylene/butylene-styrene
• polyisoprenes polybutadienes
• EPDM rubber and their analogues.
• melt viscosity typically increases with increasing molecular weight of the selected polymer.
• polymers that may more typically be characterized by melt viscosity include, e.g., polyesters, polyamides (e.g., nylons), etc.
• melt viscosity for a given polymer is measured at the temperature at which the polymer is delivered to the entrance of the die orifice. It may be preferred that, for polymers characterized by melt viscosity, the melt viscosity of the polymers used in connection with the present invention be about 100 Pascal-seconds (Pa- s) or higher.
• the present invention may also be used to melt extrude fibers using polymers with melt viscosity of 200 Pascal-seconds or higher, 300 Pascal-seconds or higher, or 400 Pascal-seconds or higher.
• an "amorphous polymer” is a polymer having little to no crystallinity usually indicated by the lack of a distinctive melting point or first order transition when heated in a differential scanning calorimeter according to ASTM D3418.
• a potential advantage of the present invention may be found in the ability to extrude polymeric fibers using a multiphase polymer as the polymer melt stream and a lubricant.
• multiphase polymer we may mean, e.g., organic macromolecules that are composed of different species that coalesce into their own separate regions. Each of the regions has its own distinct properties such as glass transition temperature (Tg), gravimetric density, optical density, etc.
• Tg glass transition temperature
• One such property of a multiphase polymer is one in which the separate polymeric phases exhibit different rheological responses to temperature. More specifically, their melt viscosities at extrusion process temperatures can be distinctly different. Examples of some multiphase polymers may be disclosed in, e.g., U.S. Patent Nos.
• multiphase refers to an arrangement of macromolecules including copolymers of immiscible monomers. Due to the incompatibility of the copolymers present, distinctly different phases or “domains" may be present in the same mass of material.
• copolymer should be understood as including terpolymers, tetrapolymers, etc.
• Some examples of polymers that may be used in extruding multiphase polymer fibers may be found within the styrenic family of multiphase copolymer resins (i.e., a multiphase styrenic thermoplastic copolymer) referred to above as AES, ASA, and ABS, and combinations or blends thereof.
• AES multiphase styrenic thermoplastic copolymer
• ASA multiphase styrenic thermoplastic copolymer
• ABS styrenic thermoplastic copolymer
• Such polymers are disclosed in U.S. Patent Nos. 4,444,841 (Wheeler), 4,202,948 (Peascoe), and 5,306,548 (Zabrocki et al.).
• the blends may be in the form of multilayered fibers where each layer is a different resin, or physical blends of the polymers which are then extruded into a single fiber.
• ASA and/or AES resins can be coextruded over ABS.
• Multiphase polymer systems can present major challenges in fiber processing because the different phases can have very different rheological responses to processing. For example, the result may be poor tensile response of multiphase polymers.
• the different rheological response of the different phases may cause wide variations in the drawing responses during conventional fiber forming processes that involve drawing or pulling of the extruded fibers. In many instances, the presence of multiple polymer phases exhibits insufficient cohesion to resist the tensile stresses of the drawing process, causing the fibers to break or rupture.
• the unique challenges that may be associated with extruding multiphase polymers may be addressed based on how the material is oriented during fiber formation. It may be preferred that, in connection with the present invention, the multiphase polymer material is squeezed or 'pushed' through the die orifice to orient the polymer materials (as opposed to pulling or drawing). As a result, the present invention may substantially reduce the potential for fracture.
• Some multiphase polymers that may be used in the methods according to the present invention are the multiphase AES and ASA resins, and combinations or blends thereof.
• AES and ASA resins include, for example, those available under the trade designations ROVEL from Dow Chemical Company, Midland, MI, and LORAN S 757 and 797 from BASF Aktiengesellschaft, Ludwigshafen, Fed. Rep. of Germany), CENTREX 833 and 401 from Bayer Plastics, Springfield, CT, GELOY from General Electric Company, Selkirk, NY, VITAX from Hitachi Chemical Company, Tokyo, Japan. It is believed that some commercially available AES and/or ASA materials also have ABS blended therein.
• Commercially available SAN resins include those available under the trade designation TYRIL from Dow Chemical, Midland, MI.
• Commercially available ABS resins include those available under the trade designation CYOLAC such as CYOLAC GPX 3800 from General Electric, Pittsfield, MA.
• the multiphase polymer fibers can also be prepared from a blend of one or more of the above-listed materials and one or more other thermoplastic polymers.
• thermoplastic polymers that can be blended with the above-listed yielding materials include, but are not limited to, materials from the following classes: biaxially oriented polyethers; biaxially oriented polyesters; biaxially oriented polyamides; acrylic polymers such as poly(methyl methacrylate); polycarbonates; polyimides; cellulosics such as cellulose acetate, cellulose (acetate-co-butyrate), cellulose nitrate; polyesters such as poly(butylene terephthalate), poly(ethylene terephthalate); fluoropolymers such as poly(chlorofluoroethylene), poly(vinylidene fluoride); polyamides such as poly(caprolactam), poly(amino caproic acid), poly(hexamethylene diamine -co-adipic acid), poly(amide-co-imide), and poly(ester-
• the polymer compositions used in connection with the present invention may include other ingredients, e.g., UV stabilizers and antioxidants such as those available from Ciba-Geigy Corp., Ardsley, NY, under the trade designation IRGANOX, pigments, fire retardants, antistatic agents, mold release agents such as fatty acid esters available under the trade designations LOXIL G-715 or LOXIL G-40 from Henkel Corp., Hoboken, NJ, or WAX E from Hoechst Celanese Corp., Charlotte, NC. Colorants, such as pigments and dyes, can also be incorporated into the polymer compositions.
• UV stabilizers and antioxidants such as those available from Ciba-Geigy Corp., Ardsley, NY, under the trade designation IRGANOX, pigments, fire retardants, antistatic agents, mold release agents such as fatty acid esters available under the trade designations LOXIL G-715 or LOXIL G-40 from Henkel Corp., Hoboken, NJ, or
• colorants may include rutile TiO 2 pigment available under the trade designation R960 from DuPont de Nemours, Wilmington, DE, iron oxide pigments, carbon black, cadmium sulfide, and copper phthalocyanine.
• the above-identified polymers are commercially available with one or more of these additives, particularly pigments and stabilizers.
• additives are used in amounts to impart desired characteristics. Preferably, they are used in amounts of about 0.02-20 wt-%, and more preferably about 0.2-10 wt-%, based on the total weight of the polymer composition.
• Another potential advantage of at least some embodiments of the present invention is the ability to extrude the polymer melt stream at a relatively low temperature.
• the average temperature of the polymer melt stream may preferably be at or below a melt processing temperature of the polymer melt stream before the polymer melt stream leaves the exit of the orifice. To do so, it may be preferred that the die temperature be controlled to a temperature that is at or below the melt processing temperature of the polymer melt stream.
• the present invention may rely on the dominance of the lubricant properties to process the polymer during extrusion, with the polymer viscosity playing a relatively minor factor in stress (pressure and temperature) response. Further, the presence of the lubricant may allow "quenching” (e.g., crystal or glass "vitrification” formation) of the polymer within the die. A potential advantage of in-die quenching may include, e.g., retaining orientation and dimensional precision of the extrudate.
• the "melt processing temperature" of the polymer melt stream is the lowest temperature at which the polymer melt stream is capable of passing through the orifices of the die within a period of 1 second or less.
• the melt processing temperature may be at or slightly above the glass transition temperature if the polymer melt stream is amorphous or at or slightly above the melting temperature if the polymer melt stream is crystalline or semicrystalline. If the polymer melt stream includes one or more amorphous polymers blended with either or both of one or more crystalline and one or more semicrystalline polymers, then the melt processing temperature is the lower of the lowest glass transition temperature of the amorphous polymers or the lowest melting temperature of the crystalline and semicrystalline polymers.
• FIG. 3 One exemplary die orifice that may be used in dies according to the present invention is depicted in the cross-sectional view of FIG. 3 in which a die plate 10 and a complementary die plate cover 12 are depicted in a cross-sectional view.
• the die plate 10 and die plate cover 12 define a polymer delivery passage 20 that is in fluid communication with an orifice 22 in the die plate 10.
• the portion of the polymer delivery passage 20 formed in the die plate cover 12 terminates at opening 16, where the polymer melt stream enters the portion of polymer delivery passage 20 formed within the die plate 10 through opening 14.
• the opening 16 in the die plate cover 12 is generally the same size as the opening 14 in the die plate 10.
• FIG. 4 depicts an enlarged view of the orifice 22 with the addition of reference letter "r" indicative of the radius of the orifice 22 and "z” indicative of the length of the orifice 22 along the axis 11.
• the orifice 22 formed in the die plate 10 may preferably converge such that the cross-sectional area (measured transverse to the axis 11) is smaller than the cross-sectional area of the entrance 24. It may be preferred that, as discussed herein, the shape of the die orifice 22 be designed such that the elongational strain rate of the polymer melt stream be constant along the length of the orifice 22 (i.e., along axis 11).
• the die orifice may have a converging semi-hyperbolic profile.
• the definition of a "semi-hyperbolic" shape begins with the fundamental relationship between volume flow, area of channel and fluid velocity.
• cylindrical coordinates are used in connection with the description of orifice 22, it should be understood that die orifices used in connection with the present invention may not have a circular cylindrical profile.
• Q is the measure of volumetric flow through the orifice
• V is the flow velocity through the orifice
• A is the cross-sectional area of the orifice 22 at the selected location along the axis 11.
• Equation (1) can be rearranged and solved for velocity to yield the following equation:
• Equation (2) Because the cross-sectional area of a converging orifice changes along the length of the channel of the orifice, the following equation can be used to describe the various relationships between variables in Equation (2):
• Equation (3) the expression for the change in velocity with the change in position down the length of the orifice also defines extensional flow ( ⁇ ) of the fluid.
• Steady or constant extensional flow may be a preferred result of flow through a converging orifice.
• An equation that defines steady or constant extensional flow may be expressed as:
• Equation (5) A generic form of the expression of Equation (5) may be the following:
• Equation (6) may be used to determine the shape of an orifice 22 as used in connection with the present invention.
• the geometric constraint of the diameter of the exit 26 of the orifice 22 it may be preferred that the geometric constraint of the diameter of the exit 26 of the orifice 22 be determined (with the understanding that exit diameter is indicative of the fiber size extruded from the orifice 22).
• the diameter of the entrance 24 of the orifice 22 may be used.
• Hencky Strain is based on extensional or engineering strain of a material being stretched. The equation presented below describes Hencky Strain for a fluid in passing through a channel, e.g., an orifice in the present invention:
• Equation 6 can be regressed for radius (area) change with the change in position down the length of the orifice 22 (along the "z" direction) to obtain the constants Ci and C 2
• Equation 6 provides the radius of the orifice at each location along the "z" dimension (r z ):
• CW Macosko "Rheology - Principles, Measurements and Applications," pp. 285-336 (Wiley- VCH Inc., New York, 1 st Ed.
• the die plate 10 also includes a lubricant passage 30 in fluid communication with a lubricant plenum 32 formed between the die plate 10 and the die plate cover 12.
• the die plate 10 and the die plate cover 12 preferably define a gap 34 such that a lubricant passed into the lubricant plenum 32 through the lubricant passage 30 will pass into the polymer delivery passage 20 from slot 36 and through opening 14. As such, the lubricant can be delivered to the orifice 22 separately from the polymer melt stream.
• the slot 36 may preferably extend about the perimeter of the polymer delivery passage 20.
• the slot 36 may preferably be continuous or discontinuous about the perimeter of the polymer delivery passage 20.
• the spacing between the die plate 10 and the die plate cover 12 that forms gap 34 and slot 36 may be adjusted based on a variety of factors such as the pressure at which a polymer melt stream is passed through the polymer delivery passage 20, the relative viscosities of the polymer melt stream and the lubricant, etc.
• the slot 36 may be in the form of an opening or openings formed by the interface of two roughened (e.g., sandblasted, abraded, etc.) surfaces forming gap 34 (or one roughened surface and an opposing smooth surface).
• FIG. 5 is a plan view of the die plate 10 with the die plate cover 12 removed. Multiple openings 14, polymer delivery passages 20, die orifices 22, and lubricant plenums 32 are depicted therein.
• the depicted polymer delivery passages 20 have a constant cross-sectional area (measured transverse to the axis 11 in FIG. 3) and are, in the depicted embodiment, circular cylinders. It should be understood, however, that the polymer delivery passages 20 and associated die orifices 22 may have any suitable cross- sectional shape, e.g., rectangular, oval, elliptical, triangular, square, etc.
• the lubricant plenums 32 extend about the perimeters of the polymer delivery passages 20 as seen in FIG. 5 such that the lubricant can be delivered about the perimeter of the polymer delivery passages 20.
• the lubricant preferably forms a layer about the perimeter of a polymer melt stream as it passes through the polymer delivery passages 20 and into the die orifices 22.
• the plenums 32 are supplied by lubricant passages 30 that extend to the outer edges of the die plate 10 as seen in FIG. 5.
• each of the plenums 32 be supplied by an independent lubricant passage 30 as seen in FIG. 5.
• control over a variety of process variable can be obtained.
• Those variables may include, for example, the lubricant pressure, the lubricant flow rate, the lubricant temperature, the lubricant composition (i.e., different lubricants may be supplied to different orifices 22), etc.
• a master plenum be used to supply lubricant to each of the lubricant passages 30 which, in turn, supply lubricant to each of the plenums 32 associated with the orifices 22.
• the delivery of lubricant to each orifice may preferably be balanced between all of the orifices.
• FIG. 6 is a schematic diagram of one system 90 that may be used in connection with the present invention.
• the system 90 may preferably include polymer sources 92 and 94 that deliver polymer to an extruder 96. Although two polymer sources are depicted, it should be understood that only one polymer source may be provided in some systems. In addition, other systems may include three or more polymer sources.
• system 90 may include any extrusion system or apparatus capable of delivering the desired polymer or polymers to the die 98 in accordance with the present invention.
• the system 90 also includes a particle source 91 that, in the depicted embodiment, provides particles to be entrained within the polymer from polymer source 92.
• the particle source 91 could input its particles into the extruder 96 (or extruders if multiple extruders are used). Regardless of the specific arrangement, it is preferred that the particles from the particle source 91 be entrained within the polymer melt stream as it is delivered to die 98.
• the system 90 further includes a lubricant apparatus 97 operably attached to the die 98 to deliver lubricant to the die in accordance with the principles of the present invention. In some instances, the lubricant apparatus 97 may be in the form of a lubricant polymer source and extrusion apparatus.
• two fibers 40 being extruded from the die 98. Although two fibers 40 are depicted, it should be understood that only one fiber may be produced in some systems, while other systems may produce three or more polymer fibers at the same time.
• FIG. 7 depicts another exemplary embodiment of a die orifice that may be used in connection with the present invention. Only a portion of the apparatus is depicted in FIG. 7 to illustrate a potential relationship between the entrance 114 of the die orifice 122 and delivery of the lubricant through gap 134 between the die plate 110 and the die plate cover 112.
• the lubricant delivered separately from the polymer melt stream is introduced at the entrance 116 of the orifice 122 through gap 134.
• the polymer melt stream itself is delivered to the entrance 116 of the die orifice 122 through polymer delivery passage 120 in die plate cover 112.
• FIG. 7 Another optional relationship depicted in the exemplary apparatus of FIG. 7 is the relative size of the entrance 114 of the die orifice 122 as compared to the size of the opening 116 leading from the polymer delivery passage 120 into the entrance 114. It may be preferred that the cross-sectional area of the opening 116 be less than the cross- sectional area of the entrance 114 to the die orifice 122. As used herein, "cross-sectional area" of the openings is determined in a plane generally transverse to the longitudinal axis 111 (which is, preferably, the direction along which the polymer melt stream moves through the polymer delivery passage and the die orifice 122).
• FIG. 8 depicts yet another potential apparatus that may be used in connection with the present invention.
• FIG. 8 is an enlarged plan view of one die orifice 222 taken from above the die plate 210 (in a view similar to that seen in FIG. 5). The entrance 216 to the die orifice 222 is depicted along with the exit 226 of the die orifice 222.
• the lubricant is delivered to the die orifice 222 through multiple openings formed at the end of channels 234a, 234b, and 234c. This is in contrast to the continuous slot formed by the gap between the die plate and the die plate cover in the embodiments described above.
• three openings for delivering lubricant are depicted, it should be understood that as few as two and more than three such openings may be provided.
• FIG. 9 depicts a flow of the polymer melt stream 40 and a lubricant 42 from the exit 26 of a die in accordance with the present invention.
• the polymer melt stream 40 and lubricant 42 are shown in cross-section, depicting the lubricant 42 on the outer surface 41 of the polymer melt stream 40. It may be preferred that the lubricant be provided on the entire outer surface 41 such that the lubricant 42 is located between the polymer melt stream 40 and the interior surface 23 of the die orifice.
• the lubricant 42 is depicted on the outer surface 41 of the polymer melt stream 40 after the polymer melt stream 40 has left the orifice exit 26, it should be understood that, in some instances, the lubricant 42 may be removed from the outer surface 41 of the polymer melt stream 40 as or shortly after the polymer melt stream 40 and lubricant 42 leave the die exit 26. Removal of the lubricant 42 may be either active or passive. Passive removal of the lubricant 42 may involve, e.g., evaporation, gravity or adsorbents. For example, in some instances, the temperature of the lubricant 42 and/or the polymer melt stream 40 may be high enough to cause the lubricant 42 to evaporate without any further actions after leaving the die exit 26. In other instances, the lubricant may be actively removed from the polymer melt stream 40 using, e.g., a water or another solvent, air jets, etc.
• the lubricant 42 may be a composition of two or more components, such as one or more carriers and one or more other components.
• the carriers may be, e.g., a solvent (water, mineral oil, etc.) that are removed actively or passively, leaving the one or more other components in place on the outer surface 41 of the polymer melt stream 40.
• the lubricant 42 may be retained on the outer surface 41 of the polymer melt stream 40.
• the lubricant 42 may be a polymer with a viscosity that is low enough relative to the viscosity of the polymer melt stream 40 such that it can function as a lubricant during extrusion.
• examples of potentially suitable polymers that may also function as lubricants may include, e.g., polyvinyl alcohols, high melt flow index polypropylenes, polyethylenes, etc.
• the lubricant 42 may act as a quenching agent to increase the rate at which the polymer melt stream 40 cools. Such a quenching effect may help to retain particular desired structures in the polymer melt stream 40 such as orientation within the polymer melt stream 40.
• it may be desirable, for example, to provide the lubricant 42 to the die orifice at a temperature that is low enough to expedite the quenching process.
• the evaporative cooling that may be provided using some lubricants may be relied on to enhance the quenching of the polymer melt stream 40.
• mineral oil used as a lubricant 42 may serve to quench a polypropylene fiber as it evaporates from the surface of the polypropylene (the polymer melt stream) after exiting the die.
• the present invention may preferably rely on a viscosity difference between the lubricant materials and the extruded polymer. Viscosity ratios of polymer to lubricant of, e.g., 40: 1 or higher, or 50: 1 or higher may preferably be a significant factor in selecting the lubricant to be used in connection with the methods of the present invention.
• the lubricant chemistry may be secondary to its rheological behavior.
• materials such as SAE 20 weight oil, white paraffin oil, and polydimethyl siloxane (PDMS) fluid are all examples of potentially suitable lubricant materials.
• PDMS polydimethyl siloxane
• Non- limiting examples of inorganic or synthetic oils may include mineral oil, petrolatum, straight and branched chain hydrocarbons (and derivatives thereof),, liquid paraffins and low melting solid paraffin waxes, fatty acid esters of glycerol, polyethylene waxes, hydrocarbon waxes, montan waxes, amide wax, glycerol monostearate. etc.
• oils and fatty acid derivatives thereof may also be suitable lubricants in connection with the present invention.
• Fatty acid derivatives of oils can be used, such as, but not limited to, oleic acid, linoleic acid, and lauric acid.
• Substituted fatty acid derivatives of oils may also be used, such as, but not limited to, oleamide, propyl oleate and oleyl alcohol (it may be preferred that the volatility of such materials is not so high so as to evaporate before extrusion).
• Examples of some potentially suitable vegetable oils may include, but not limited to, apricot kernel oil, avocado oil, baobab oil, black currant oil, calendula officinalis oil, cannabis sativa oil, canola oil, chaulmoogra oil, coconut oil, corn oil, cottonseed oil, grape seed oil, hazelnut oil, hybrid sunflower oil, hydrogenated coconut oil, hydrogenated cottonseed oil, hydrogenated palm kernel oil, jojoba oil, kiwi seed oil, kukui nut oil, macadamia nut oil, mango seed oil, meadowfoam seed oil, mexican poppy oil, olive oil, palm kernel oil, partially hydrogenated soybean oil, peach kernel oil, peanut oil, pecan oil, pistachio nut oil, pumpkin seed oil, quinoa oil, rapeseed oil, rice bran oil, safflower oil, sasanqua oil, sea buckthorn oil, sesame oil, shea butter fruit oil, sisymbrium i
• Suitable lubricant materials may include, e.g., saturated aliphatic acids including hexanoic acid, caprylic acid, decanoic acid, undecanoic acid, lauric acid, myristic acid, palmitic acid and stearic acid, unsaturated aliphatic acids including oleic acid and erucic acid, aromatic acids including benzoic acid, phenyl stearic acid, polystearic acid and xylyl behenic acid and other acids including branched carboxylic acids of average chain lengths of 6, 9, and 11 carbons, tall oil acids and rosin acid, primary saturated alcohols including 1-octanol, nonyl alcohol, decyl alcohol, 1-decanol, 1- dodecanol, tridecyl alcohol, cetyl alcohol and 1 -heptadecanol, primary unsaturated alcohols including undecylenyl alcohol and oleyl alcohol, secondary alcohols including 2- octanol, 2- undecan
• hydroxyl-containing compounds may include polyoxyethylene ethers of oleyl alcohol and a polypropylene glycol having a number average molecular weight of about 400.
• Still further potentially useful liquids may include cyclic alcohols such as 4, t- butyl cyclohexanol and methanol, aldehydes including salicyl aldehyde, primary amines such as octylamine, tetradecylamine and hexadecylamine, secondary amines such as bis-(l-ethyl-3 -methyl pentyl) amine and ethoxylated amines including N-lauryl diethanolamine, N-tallow diethanol- amine, N-stearyl diethanolamine and N-coco diethanolamine.
• Additional potentially useful lubricant materials may include aromatic amines such as N- sec-butylaniline, dodecylaniline, N,N-dimethylaniline, N,N- diethylaniline, p- toluidine, N-ethyl-o-toluidine, diphenylamine and aminodiphenylmethane, diamines including N-erucyl-l,3-propane diamine and 1,8-diamino-p-methane, other amines including branched tetramines and cyclodecylamine, amides including cocoamide, hydrogenated tallow amide, octadecylamide, eruciamide, N,N-diethyl toluamide and N- trimethylopropane stearamide, saturated aliphatic esters including methyl caprylate, ethyl laurate, isopropyl myristate, ethyl palmitate, isoproprop
• Yet other potentially useful lubricant materials may include polyethylene glycol esters including polyethylene glycol (which may preferably have a number of average molecular weight of about 400), diphenylstearate, polyhydroxylic esters including castor oil (triglyceride), glycerol monostearate, glycerol monooleate, glycol distearate glycerol dioleate and trimethylol propane monophenylstearate, ethers including diphenyl ether and benzyl ether, halogenated compounds including hexachlorocyclopentadiene, octabromobiphenyl, decabromodiphenyl oxide and 4-bromodiphenyl ether, hydrocarbons including 1-nonene, 2-nonene, 2-undecene, 2-heptadecene, 2- nonadecene, 3-eicosene, 9-nonadecene, diphenylmethane, triphenylmethane and
• Still further potentially useful lubricants may include phosphorous compounds including trixylenyl phosphate, polysiloxanes, Muget hyacinth (An Merigenaebler, Inc), Terpineol Prime No. 1 (Givaudan-Delawanna, Inc), Bath Oil Fragrance #5864 K (International Flavor & Fragrance, Inc), Phosclere P315C (organophosphite), Phosclere P576 (organophosphite), styrenated nonyl phenol, quinoline and quinalidine.
• phosphorous compounds including trixylenyl phosphate, polysiloxanes, Muget hyacinth (An Merigenaebler, Inc), Terpineol Prime No. 1 (Givaudan-Delawanna, Inc), Bath Oil Fragrance #5864 K (International Flavor & Fragrance, Inc), Phosclere P315C (organophosphite), Phos
• Oils with emulsifier qualities may also potentially be used as lubricant materials, such as, but not limited to, neatsfoot oil, neem seed oil, PEG-5 hydrogenated castor oil, PEG-40 hydrogenated castor oil, PEG-20 hydrogenated castor oil isostearate, PEG-40 hydrogenated castor oil isostearate, PEG-40 hydrogenated castor oil laurate, PEG-50 hydrogenated castor oil laurate, PEG-5 hydrogenated castor oil triisostearate, PEG-20 hydrogenated castor oil triisostearate, PEG-40 hydrogenated castor oil triisostearate, PEG- 50 hydrogenated castor oil triisostearate, PEG-40 jojoba oil, PEG-7 olive oil, PPG-3 hydrogenated castor oil, PPG-12-PEG-65 lanolin oil, hydrogenated mink oil, hydrogenated olive oil, lanolin oil, maleated soybean oil, musk rose oil, cashew nut oil, castor oil, dog rose hips oil, emu oil,
• the moduli of the fibers of the invention were measured using the procedures described in ASTM-D2653-01. 16 mm diameter roller grips (MTS 100-034-764) were used with a 14 cm grip separation and a crosshead speed of 25.4 cm/min. A 500 N load cell was used. The diameters of the fibers were measured using an Ono Sokki thickness gauge. 5 replicates were run and averaged.
• the mass flow rate was measured by a basic gravimetric method.
• the exiting extrudate was captured in a pre-weighed aluminum tray for a period of 80 seconds.
• the difference between the total weight and the weight of the tray was measured in grams or kilograms.
• melt flow indices of the polymers were measured according to ASTM D 1238 at the conditions specified for the given polymer type.
• a polymeric fiber was produced using apparatus similar to that shown in FIG. 6.
• a single orifice die as shown in FIG. 7 was used.
• the die orifice was circular and had an entrance diameter of 1.68 mm, an exit diameter of 0.76 mm, a length of 12.7 mm and a semi-hyperbolic shape defined by the equation:
• z is the location along the axis of the orifice as measured from the entrance and r z is the radius at location z.
• Polypropylene homopolymer (FINAPRO 5660, 9.0 MFI, Atofina Petrochemical Co., Houston, TX) was extruded with a 3.175 cm single screw extruder (30: 1 L/D) using a barrel temperature profile of 177°C- 232°C- 246°C and an in-line ZENITH gear pump (1.6 cubic centimeters/revolution (cc/rev)) set at 19.1 RPM.
• the die temperature and melt temperature were approximately 220 0 C.
• Chevron SUPERLA white mineral oil #31 as a lubricant was supplied to the entrance of the die using a second ZENITH gear pump (0.16 cc/rev) set at 30 RPM.
• the molten polymer pressure and corresponding mass flow rate of the extrudate are shown in Table 1 below.
• the pressure transducer for the polymer was located in the feed block just above the die at the point where the polymer was introduced to the die.
• the lubricant pressure transducer was located in the lubricant delivery feed line prior to introduction to the die. A control sample was also run without the use of lubricant.
• EXAMPLE 2 A polymeric fiber was produced as in Example 1 except that a die similar to that depicted in FIG. 3 was used.
• the die orifice had a circular profile with an entrance diameter of 6.35 mm, an exit diameter of 0.76 mm, a length of 10.16 mm and a semi- hyperbolic shape defined by Equation (8) as described herein.
• a polymeric fiber was produced as in Example 1 except that a die as shown in Figure 2 was used.
• the die orifice had a circular profile with an entrance diameter of 6.35 mm, an exit diameter of 0.51 mm, a length of 12.7 mm and a semi-hyperbolic shape defined by Equation (8).
• Polyurethane (PS440-200 Huntsman Chemical, Salt Lake City, UT) was used to form the fiber.
• the polymer was delivered with a 3.81 cm single screw extruder (30: 1 L/D) using a barrel temperature profile of 177°C- 232°C- 246°C and an in-line ZENITH gear pump (1.6cc/rev) set at 19.1 RPM.
• the die temperature and melt temperature was approximately 215°C.
• Chevron SUPERLA white mineral oil #31 as a lubricant was supplied to the entrance of the die via two gear pumps in series driven at 99 RPM and 77 RPM respectively. Molten polymer pressure and mass flow rate of the extrudate is shown in Table 1 below. A control sample was also run without the use of lubricant.
• Table 1 shows that at similar melt pressures, substantially higher mass flow rates may be obtained using the invention process (Example 1), and at similar mass flow rates, polymer may be extruded at significantly lower pressures (Example T). As seen in Example 3, melt pressure may be significantly reduced and mass flow rate substantially increased simultaneously when using the invention process.
• a polymeric fiber was produced using the die of Example 1.
• High molecular weight polyethylene (Type 9640, 0.2 MI, Chevron Phillips Chemical Co., Houston, TX) was extruded with a 38 mm single screw extruder (30: 1 L/D, 9 RPM) using a barrel temperature profile of 177°C- 200 0 C- 218°C and an in-line ZENITH gear pump (1.6 cubic centimeters/revolution (cc/rev)) set at 3.7 RPM.
• the die temperature and melt temperature were approximately 218°C.
• Chevron SUPERLA white mineral oil #31 (Chevron USA Inc., Houston, TX) as a lubricant was supplied to the entrance of the die using a ZENITH dual gear single feed gear pump (0.16 cc/rev) set at 80 RPM. The extruded fiber was collected at the die exit manually and coiled by hand.
• the molten polymer pressure varied between 241 N/cm 2 (350 lbs/in 2 ) and 550 N/cm 2 (798 lbs/in 2 ) at a mass flow rate of 2.0 - 2.5 kg/hr (4.5-5.5 lbs/hr).
• the pressure transducer for the polymer was located in the feed block just above the die at the point where the polymer was introduced to the die.
• the lubricant pressure transducer was located in the lubricant delivery feed line prior to introduction to the die.
• EXAMPLE 5 A polymeric fiber was produced as in Example 1.
• the die orifice had a circular profile with an entrance diameter of 6.35 mm, an exit diameter of 0.76 mm, a length of 127 mm and a semi-hyperbolic shape defined by Equation (8) as described herein.
• a high molecular weight fractional melt index polyethylene (HD7960.13, 0.06 MI, ExxonMobil Chemical Inc., Houston, TX) was extruded using a 19 mm single screw (30: 1 L/D, 12 RPM) extruder using a barrel temperature profile of 270 0 C- 255°C- 240 0 C fitted with a 0.16 cubic centimeters per revolution (0.16 cc/rev) gear pump operating at 6 RPM.
• the die temperature and melt temperature were approximately 218°C.
• Chevron SUPERLA white mineral oil #31 (Chevron USA Inc., Houston, TX) as a lubricant was supplied to the entrance of the die using a Lorimer "air over oil” pneumatic high pressure pump (H. Lorimer Corp., Longview, TX).
• the extruded fiber was then quenched in a water bath (approximately 20 0 C) positioned approximately 5 cm beneath the die exit at a rate of 15 meter/min.
• the fiber was then length oriented in-line between two pull rolls by immersing the fiber in a hot water bath (79°C) with a draw ratio between the two pull rolls of approximately 9: 1.
• the oriented fiber was then run over a heated platen set at 177°C to relax (heat set) the fiber and then wound onto a core.
• the average fiber diameter was 0.305 mm.
• the modulus of the fiber was measured to be 205 kN/cm 2 with a break tensile force of 46 kN.
• a polymeric fiber was produced as in Example 1 except a high molecular weight elastomeric polyethylene (ENGAGE 8100, 1.0 MI, Dow Chemical Co., Midland, MI) was used to form the fiber.
• the polymer was delivered with a 38 mm single screw extruder (32: 1 L/D, 14 RPM) using a barrel temperature profile of 177°C- 200 0 C- 218°C and an in-line ZENITH gear pump (1.6cc/rev) set at 8 RPM resulting in a polymer flow rate of approximately 2.4 kg/hr.
• the die temperature and melt temperature was approximately 218°C.
• Chevron SUPERLA white mineral oil #31 as a lubricant was supplied to the entrance of the die using a ZENITH dual gear single feed gear pump (0.16 cc/rev) set at 75 RPM. The extruded fiber was collected at the die exit manually and coiled by hand.
• EXAMPLE 7 A polymeric fiber was produced as in Example 1 except an amorphous glassy polycarbonate (MACROLON 2407, Bayer Chemical Co., Leverkusen, Germany) was used to form the fiber.
• the polymer was delivered with a 38 mm single screw extruder (32: 1 L/D, 14 RPM) using a barrel temperature profile of 177°C- 200 0 C- 229°C and an in-line ZENITH gear pump (1.6cc/rev) set at 8 RPM resulting in a polymer flow rate of approximately 2.4 kg/hr.
• the die temperature and melt temperature was approximately 229°C.
• Chevron SUPERLA white mineral oil #31 as a lubricant was supplied to the entrance of the die using a ZENITH dual gear single feed gear pump (0.16 cc/rev) set at 75 RPM. The extruded fiber was collected at the die exit manually and coiled by hand.
• a polymeric fiber was produced as in Example 5 except that a nylon-6 polyamide (ULTRAMID B4, BASF Corp., Wyandotte, MI) was extruded using a 19 mm single screw (30: 1 L/D, 18 RPM) extruder using a barrel temperature profile of 250 0 C- 300 0 C- 300 0 C fitted with a 0.16 cubic centimeters per revolution (0.16 cc/rev) gear pump operating at 8 RPM.
• the die temperature and melt temperature were approximately 260 0 C.
• Chevron SUPERLA white mineral oil #31 (Chevron USA Inc., Houston, TX) as a lubricant was supplied to the entrance of the die using a Lorimer "air over oil” pneumatic high pressure pump (H.
• a 3 mm diameter (ID) copper tubing was used to supply the lubricant from the pump to the die.
• the tubing was wrapped 2.5 times around the 7.6 cm diameter die prior to the entry port into the die. This was done to heat the temperature of the lubricant up to that of the die.
• the extruded fiber with a diameter of approximately 1 millimeter was then quenched in a water bath (approximately 20 0 C) positioned approximately 2.5 cm beneath the die exit at a rate of 2.4 meter/minute.
• the fiber was then length oriented in-line between two pull rolls by immersing the fiber in a hot water bath (79°C) with a draw ratio between the two pull rolls of approximately 4: 1.
• the oriented fiber was then run over a heated platen set at 177°C to relax (heat set) the fiber and then over a second heated platen set at 121 0 C to anneal the fiber and then wound onto a core.
• the modulus of the fiber was measured to be 226 kN/cm 2 .
• EXAMPLE 9 A polymeric fiber was produced as in Example 8 except that significantly lower process temperatures were used to obtain a melt temperature slightly above the polymer melting point (230 0 C) resulting in significantly higher modulus fibers.
• the nylon was extruded using a barrel temperature profile of 240 0 C- 250 0 C- 240 0 C.
• the melt pump was set at 235°C, the die feed block at 230 0 C and the die at 225°C.
• the modulus of the fiber was measured to be 765 kN/cm .
• a polymeric fiber was produced as in Example 1 except two extruders were used to feed two materials to a sheath/core feedblock resulting in a bicomponent coextruded fiber.
• Polypropylene homopolymer (FINAPRO 5660, 9.0 MFI, Atofina Petrochemical
• the polymer was delivered with a 25 mm single screw extruder (24: 1 L/D) using a barrel temperature profile of 177°C- 200 0 C- 232°C and an in-line ZENITH gear pump (1.6cc/rev) set at 24 RPM.
• FINAPRO 5660 pigmented with 2% orange color concentrate (Type 66Y163, Penn Color Co., Doylestown, PA) was used to form the sheath of the fiber.
• the polymer was delivered with a 19 mm single screw extruder using a barrel temperature profile of 177°C-195°C- 215°C-232°C and an in-line ZENITH gear pump (1.6cc/rev) set at 24 RPM.
• the melt pump was set at 232°C, the die feed block at 232°C and the die at 232°C.
• the die feed block consisted of a series of 0.5 mm thick machined plates stacked to provide a dual feed plate die as is well known in the art of coextruded fibers.
• the lubricant introduction manifold was attached at the bottom of the plate stack.
• Universal Trans Hydraulic oil (Mills Fleet Farm Inc., Brainerd, MN) was used as the lubricant and was supplied to the entrance of the die using a ZENITH dual gear single feed gear pump (0.16 cc/rev) set at 80 RPM.
• the extruded fiber was collected at the die exit manually and coiled by hand.
• EXAMPLE 11 A polymeric fiber was produced as in Example 1 except a multiphase acrylonitrile- styrene-butylacrylate polymer (CENTREX 833, Marine White, 3 MFI, Bayer Corp., Leverkusen, Germany) was used to form the fiber.
• the polymer was delivered with a 38 mm single screw extruder (32: 1 L/D, 14 RPM) using a barrel temperature profile of 177°C- 200 0 C- 218°C and an in-line ZENITH gear pump (1.6cc/rev) set at 8 RPM resulting in a polymer flow rate of approximately 2.4 kg/hr.
• the die temperature and melt temperature was approximately 218°C.
• Chevron SUPERLA white mineral oil #31 as a lubricant was supplied to the entrance of the die using a ZENITH dual gear single feed gear pump (0.16 cc/rev) set at 75 RPM. The extruded fiber was collected at the die exit manually and coiled by hand.
• a polymeric fiber was produced as in Example 10 except a nylon 12 (GRILAMID
• Chevron SUPERLA white mineral oil #31 as a lubricant was supplied to the entrance of the die using a ZENITH dual gear single feed gear pump (0.16 cc/rev) set at 80 RPM.
• the extruded fiber was collected at the die exit manually and coiled by hand.
• the outer surface of the fiber was very rough with a large amount of abrasive at or near the outer surface of the fiber.

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• 2006
  • 2006-06-28 US US11/427,094 patent/US20080003430A1/en not_active Abandoned
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