Classifications

• • 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
  • D01D5/24—Formation of filaments, threads, or the like with a hollow structure; Spinnerette packs therefor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
  • B01D67/0002—Organic membrane manufacture
  • B01D67/0009—Organic membrane manufacture by phase separation, sol-gel transition, evaporation or solvent quenching
  • B01D67/0011—Casting solutions therefor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
  • B01D69/08—Hollow fibre membranes
  • B01D69/085—Details relating to the spinneret
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
  • B01D69/08—Hollow fibre membranes
  • B01D69/087—Details relating to the spinning process
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
  • B01D71/06—Organic material
  • B01D71/76—Macromolecular material not specifically provided for in a single one of groups B01D71/08 - B01D71/74
  • B01D71/78—Graft polymers
• • 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
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/06—Wet spinning methods
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • 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
  • D01F6/66—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyethers
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
  • D01F6/76—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from other polycondensation products
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2323/00—Details relating to membrane preparation
  • B01D2323/06—Specific viscosities of materials involved
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2323/00—Details relating to membrane preparation
  • B01D2323/219—Specific solvent system
  • B01D2323/22—Specific non-solvents or non-solvent system
• • 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
  • Y10T428/2973—Particular cross section
  • Y10T428/2975—Tubular or cellular

Definitions

• the invention relates to a process for the preparation of hyperbranched hollow filaments and hollow fibers and particularly to a process for the preparation of hyperbranched poly- ethersulfone (HPES) hollow filaments and hollow fibers made thereof.
• HPES hyperbranched poly- ethersulfone
• Fibers are often composed of one or several filaments.
• the primary material that is ob- tained e.g. after a spinning process is called a filament.
• Filaments can be converted to more defined filaments, e.g. fibers.
• Fibers can consist of one or more defined filaments.
• a hollow filament or fiber is a cylindrical filament or fiber that exhibits one or more hollows in its cross section.
• the importance of the preparation of hollow filaments or fibers and hollow fiber spinning e.g. for vast membrane applications is well recognized for decades. Hollow fiber membranes are of particular interest since they find applications in textile industry, chemistry or medicine (dialysis). To date, both melt and solution spinning are the most widely implemented techniques in hollow filament or fiber fabrication.
• the fiber production rate is one of the major parameters to determine maximum production capacity and profitability e.g. in the membrane industry.
• limitations caused by instabilities in the polymer flow lead to technical problems within the production line itself or fabricate un- desirable final products which increase production costs.
• Some issues encompassed within the hollow filament or fiber spinning instability include draw resonance, necking, capillary break-up, irregular cross section and melt fracture or extrudate distortion. Most of the mentionend phenomena lead to a breakage of the filament or fiber during the spinning process or generate a non-uniform cross-sectional diameter along the spun fibers.
• the spinning instability that characteristically shows up with melt fracture or extrudate distortion normally takes place in the form of a distorted, gross or wavy polymer flow.
• DE-A 195 1 1 150 discloses an apparatus for multi-filament spinning of hollow fibers, like e.g. regenerated cellulose.
• Two fluids from the spinning stream are combined into a stream to be drawn through a precipitation bath and following baths, followed by drying and winding.
• the jets to form the hollow fibres have a channel filler to fill the interior of the hollow fibres after emerging from a capillary.
• the capillaries are in hollow zones of the jets with a centering and/or mounting.
• the hollow zones form a series of back-up zones, interlinked by flow sections with a narrow cross section.
• a conical end section is at the final back-up zone, with a transit in a parallel ring gap.
• EP-A 0 341 978 discloses a hollow fiber with a plurality of members projecting from its out- er surface in an arc turned back on itself.
• This hollow fiber is formed from a spinneret having a segmented orifice wherein each segment comprises a first portion in the form of an arc curved about the center of the orifice, a second portion extending from the first and connected to a third portion which is in the form of a reverse curve with respect to the first.
• the use of these hollow fibers for medicinal applications or textiles is men- tioned.
• hyperbranched materials In recent years, polymers with highly branched structures are gaining popularity due to their large number of functional groups and high surface reactivity in contrast to their linear analogues.
• hyperbranched materials an outgrowths of the invention of dendrimers that have many short chains linked together and form a large polymer which average branch length is much smaller than the overall degree of polymerization, are considerably new materials.
• much progress has been achieved in the structural understanding and the synthesis of hyperbranched materials, much of the fundamental under- standing, especially the industrial application of these hyperbranched polymers, especially of hyperbranched hollow fibers, are still in the stage of infancy.
• HPES hyperbranched polyethersulfone
• LPES linear polyethersulfone
• the present invention is directed to a process for the preparation of a hollow filament (F) based on one or several molten or dissolved hyperbranched polymers (P) and potentially one or several further polymers (FP), characterized in that the molten or dissolved hyperbranched polymer (P) or the mixture of the hyperbranched polymer (P) with the further polymer (FP) is passed through one or several spinnerets (S), wherein the ratio between the spinneret die-length (L) and the die-channel (deltaD) is between 0.1 and 9.5. It is also possible to use a solution of one or several hyperbranched polymers (P) in combination with one or sevaral further polymers (FP) e.g. polyvinylpyrrolidone (PVP), polyamide (PA), polyethylenglycol (PEG), polyethyleneimine (PEI).
• PVP polyvinylpyrrolidone
• PA polyamide
• PEG polyethylenglycol
• PEI polyethylenei
• the further polymer (FP) is amorph and/or is a high molecular polymer with a molecular weight of greater than 10.000 g/mol.
• hyperbranched polymer (P) In another preferred embodiment of the invention only one hyperbranched polymer (P) is used in a solution without a further polymer (FP) for the preparation of hollow filaments (F). In another preferred embodiment of the invention, one or several hyperbranched polymers (P) are used in combination with at least one further polymer (FP) for the preparation of hollow filaments (F).
• the spinnerets (S) used according to the invention can have different geometries (G) and sizes.
• the spinnerets (S) can be made of metal, glass, plastic or other materials. Useful materials for spinnerets are known for the person skilled in the art.
• the hyperbranched polymer (P) is selected from the group consisting of polyethersulfone, polyester, polyamide, polyolefin, polyure- thane, polyimide and polyimide-amide, polyetherimide, polysulfone and polyacrylnitril. In principle, also other hyperbranched polymers can be used for the preparation of hollow filaments.
• the hyperbranched polymer (P) is a hyperbranched polyethersulfone.
• the degree of hyperbranching in the hyperbranched polymer (P) is between 0.2 and 8 %. In particular, the degree of hyperbranching is from 0.4 to 6 %, often, it is from 0.5 to 4 %. In terms of the present invention the degree of hyperbranching in the hyperbranched polymer is the percentage (mol-%) of the hyperbranched units in relation to the total quantity (mol-%) of polymer(s) excluding the polymer-solvents.
• the process for the preparation of a hollow filament according to the invention encompass the step, wherein the hyperbranched polymer (P) is dissolved in a protic solvent, in particular with a polymer concentration in the solution between 10 and 40 wt%, and then passed through one or several spinnerets (S).
• a protic solvent in particular with a polymer concentration in the solution between 10 and 40 wt%
• the solvents wherein the hyperbranched polymer (P) can be dissolved preferably are selected from the group consisting of dimethylacetamide (DMAC), dimethylformamide (DMF), N-Methyl-2-pyrrolidon (NPM) and Dimethylsulfoxid (DMSO).
• the solution can furthermore comprise polyvinylpyrrolidone (PVP) or one or several other hydrophilic polymers, preferably with molecular weights in the range of 600 and 1 Million Da.
• the weight percentages of these polymers in the solution preferably are from 1 to 20 wt%.
• the spinneret (S) used for the preparation of a hollow filament or fiber can have a geometry (G) that is selected from the group consisting of:
• Fig. 1 shows a spinneret (S) with a straight channel geometry (geometry Gl) with the die-length (L 1 ), the outer diameter (OD 1 ) which is the general outer diameter of the whole spinneret exit and the inner diameter (ID 1 ).
• Fig. 2 shows a spinneret (S) with a double-cone form geometry with an enlarged channel (geometry Gil) with the die-length (l_”), the outer diameter (OD”), the inner diameter (ID”) and with the angle (a 11 ).
• Fig. 3 shows a spinneret (S) with a cone-form geometry with a conical exit (geometry
• Fig. 4 shows a spinneret (S) with a round form geometry with a round exit channel (geometry GIV) with the die-length (L IV ), the outer diameter (OD lv ), the inner diameter
• Fig. 5 shows a common spinneret (geometry GO) with the die-length (L°), the outer diameter (OD°) and the inner diameter (ID 0 ).
• Fig. 6 shows a common dry-jet-wet-spinning apparatus (W) with the dissolved hyper- branched polymer (P) inside a vessel (V), the spinnerets (S) where the dissolved hy- perbranched polymer (P) is passed through, the air gap (A), the precipitation bath (B), the primary hollow filament (F1 ) and the obtained hollow filament (F).
• W dry-jet-wet-spinning apparatus
• the spinneret (S) with geometry (Gl) has a die- length (L 1 ) between 0.2 to 4.5 mm and a L'/Delta-D 1 ratio between 0.8 to 2.0.
• the spinneret (S) with geometry (Gil) has a die-length (L") between 0.2 to 4.5 mm and a l_"/Delta-D" ratio between 1 .2 to 3.0.
• the spinneret (S) with geometry (GIN) has a die-length (L 111 ) between 0.2 to 4.5 mm and a L l "/Delta-D l " ratio between 1 .1 to 2.
• the spinneret (S) with geometry (GIV) has a die-length (L IV ) between 0.2 to 4.5 mm and a L lv /Delta-D lv ratio between 1.1 to 2.
• the non-solvent used for the precipitation bath (B) can be a linear or branched alcohol (e.g. a C 2 to Cio-alcohol) or another protic non-solvent.
• the non- solvent taken for the precipitation bath (B) is isopropanol (I PA).
• the non-solvents also can be a mixture of two or more protic non-solvents.
• the air gap (A) is defined as the distance between the spinneret-exit and the precipitation bath (B).
• the viscosity of the molten or dissolved hyperbranched polymer (P) during the process often is between 15 and 30 Pa * s. Depending on the polymers used for the preparation of hollow filaments, the viscosity can also be below 15 Pa * s or higher than 30 Pa * s.
• a bore fluid composition is used.
• the bore fluid composition is defined in terms of the present invention as a composition of a fluid taken for the produced hollow in the hollow filament during the spinning process.
• the bore fluid passes the inner hollow (inner diameter ID)) of the spinneret (S), preferably with bore fluid flow rate in the range of 1 to 2 ml/min.
• bore fluids are known in the art.
• the bore fluid compositions in the process can e.g. comprise of 0 to 90 wt% of the solvent N-methyl-2-pyrrolidone (NMP) in water or of pure water.
• NMP N-methyl-2-pyrrolidone
• the bore fluid used in the process described above consists of 10 to 90 wt% of NMP and 10 to 90 wt% of water.
• the preferred compositions of bore fluids are non-solvent rich bore fluid compositions. Preferably they can contain from 100 wt% to 20 wt% water for example with the use of spinnerets (S) with the geometries (GIN) or (GIV). Also other bore fluid mixtures are possible.
• the steps a) to c) of the process can be carried out at various spinning temperatures.
• the spinning temperature in the process for the preparation of a hollow filament (and in particular step c)) preferably is from 25°C to 150°C.
• the preferred temperature range is from 50° to 100°C.
• the primary hollow filament (F1 ) and the hollow filament (F) in the steps e) to g) of the process can taken up with a take-up speed that is defined as the speed to be taken for taking up the prepared primary hollow filament (F1 ) after the hyperbranched polymer (P) is pressed through the spinneret (S), lead through an air gap (A) and lead into a precipitation bath (B).
• the take up speed in the process for the preparation of a hollow filament (F) can vary e.g. from 1 to 80 m/min.
• the preferred take-up speed is from 5 to 40 m/min, more preferred from 6 to 10 m/min. Often a take-up speed of greater than 8 m/min is used.
• the hollow filaments (F) prepared according to a process as described in the present in- vention can be used e.g. for the preparation of various polymer products. Further, the present invention is directed to the use of hollow filaments (F) prepared (or obtainable) according to a process described in the present invention. In a preferred embodiment of the present invention, the hollow filaments (F) prepared according to a process as described, are used for the preparation of fibres and/or membranes. Hollow filaments (F) can be prepared by a process according to the present invention. Further, the present invention is directed to hollow filaments (F) prepared (or obtainable) according to a process described in the present invention. The hollow filaments (F) or hollow fibers can be used for the preparation of membranes that can be applied e.g.
• This example describes the utilization of various spinneret designs to minimize die swell and extrudate distortion in hyperbranched polyethersulfone (HPES) hollow fiber spinning.
• HPES hyperbranched polyethersulfone
• a linear polyethersulfone (LPES) product (Ultrason ® E6020P of BASF SE) as taken for the experiments composed of 100 mol% linear units.
• a hyperbranched polyethersulfone (HPES) as taken for the experiments composed of 2 mol% branching units (2 % hyperbranching degree) and 98 mol% linear units, was supplied by BASF SE, Germany. Both, LPES and HPES, were used separately and compared and described in the following examples. Their chemical structures are shown in the following scheme.
• NMP N-methyl-2-pyrrolidone
• IPA isopropanol
• PVP polyvinylpyrrolidone
• LPES linear polyethersulfone
• HPES hyperbranched poly- ethersulfone
• PVP polyvinylpyrrolidone
• Certain amount of dried LPES or HPES was then dissolved slowly into a chilled NMP according to the desired weight percentage.
• PVP was added to the polymer dope solution to make its final composition constant at 16/10/74 wt% polyethersulfone (PES)/PVP/NMP.
• the polymer solutions were stirred continuously at least 1 day before hollow fiber spinning to remove bubbles.
• LES Linear polyethersulfone
• n is a number > 1.
• Fig. 6 shows a typical dry-jet-wet-spinning apparatus. The dope solution and bore-fluid were extruded at a specified flow rate through a spinnret using two ISCO syringe pumps. The nascent fibers exiting from the spinneret were snapshot by a Canon EOS 350D digital camera equipped with a micro lens (MP-E 65 mm/f/2.8 1 -5X) and the pictures were evaluated to compare the results.
• MP-E 65 mm/f/2.8 1 -5X micro lens
• spinnerets (S) with various designs were extruded through spin- nerets(S) with various designs.
• the spinneret (S) with geometry (Gil) results in the most pronounced die swell for both LPES and HPES polymer solutions.
• the flow stability is enhanced in the spinneret (S) with the geometry (GIN) and (GIV) in comparison with that of the common spinneret (S) with geometry (GO) and the spinneret (S) with geometry (Gl).
• the spinnerets (S) with the geometry (GIN) and (GIV) show the most improved flow stability as well as less die swell compared to the other spinneret designs due to reduced overall shear stress and enhanced compression stress.
• This example describes the optimization of bore fluid composition to minimize die swell and extrudate distortion in the HPES hollow fiber spun with various spinneret designs.
• the di- mensions of the used spinnerets (S) with different geometries are the same as in example 1 and shown in Table 2.
• This example describes the combination of proper die geometry design and optimum spinning parameters to suppress die swell and extrudate distortion in the HPES hollow fiber spinning.
• the dimensions of the used spinnerets (S) with different geometries are the same as in example 1 and shown in Table 2.
• the take-up speed in the fiber spinning is a crucial parameter which plays an important role on hollow fiber dimension and morphology because of the external work (or elongational stress) on the as-spun fibers.
• This work (or stress) along spinning direction may counterbalance the instability force in the transversal direction, thus align the polymer chains in the spinning direction and suppress the flow instability and smoothen any distortion. As a result, it can be expected that less die swell and better flow instability can be achieved.
• the parameters are listed in Table 4.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Textile Engineering (AREA)
• Mechanical Engineering (AREA)
• General Chemical & Material Sciences (AREA)
• Dispersion Chemistry (AREA)
• Manufacturing & Machinery (AREA)
• Artificial Filaments (AREA)
• Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
• Separation Using Semi-Permeable Membranes (AREA)

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• 2010
  • 2010-10-26 WO PCT/EP2010/066141 patent/WO2011051273A2/en not_active Ceased
  • 2010-10-26 KR KR1020127010910A patent/KR20120123650A/ko not_active Withdrawn
  • 2010-10-26 US US13/504,717 patent/US9234302B2/en not_active Expired - Fee Related
  • 2010-10-26 JP JP2012535783A patent/JP5808333B2/ja not_active Expired - Fee Related
  • 2010-10-26 ES ES10768955.6T patent/ES2459191T3/es active Active
  • 2010-10-26 BR BR112012010098A patent/BR112012010098A2/pt not_active IP Right Cessation
  • 2010-10-26 EP EP10768955.6A patent/EP2494101B1/en not_active Not-in-force
  • 2010-10-26 CN CN201080048198.0A patent/CN102713029B/zh not_active Expired - Fee Related

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