WO2016202813A1 - Process for the preparation of polyolefin fibers - Google Patents
Process for the preparation of polyolefin fibers Download PDFInfo
- Publication number
- WO2016202813A1 WO2016202813A1 PCT/EP2016/063661 EP2016063661W WO2016202813A1 WO 2016202813 A1 WO2016202813 A1 WO 2016202813A1 EP 2016063661 W EP2016063661 W EP 2016063661W WO 2016202813 A1 WO2016202813 A1 WO 2016202813A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- polyolefin
- fibers
- molecular weight
- process according
- copolymers
- Prior art date
Links
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
- D01D1/00—Treatment of filament-forming or like material
- D01D1/02—Preparation of spinning solutions
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/18—Formation of filaments, threads, or the like by means of rotating spinnerets
-
- 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
- D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
-
- 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
- D01F6/28—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/30—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds comprising olefins as the major constituent
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/724—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged forming webs during fibre formation, e.g. flash-spinning
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
- D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
- D10B2321/0211—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene high-strength or high-molecular-weight polyethylene, e.g. ultra-high molecular weight polyethylene [UHMWPE]
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
- D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
Definitions
- the present invention relates to a process for the preparation of polyolefin fibers, preferably nanofibers, in particular for the preparation of polyethylene fibers.
- the present invention also relates to polyolefin fibers obtained therewith.
- nanofiber webs find use in a wide range of applications such as filtration, membrane separation, protective military clothing, biosensors, wound dressings, and scaffolds for tissue engineering.
- applications such as filtration, membrane separation, protective military clothing, biosensors, wound dressings, and scaffolds for tissue engineering.
- the application of nanofibers has been limited due to its poor mechanical properties.
- Electrospinning and melt-blown spinning are the most widely used spinning methods to prepare polymeric fibers. Electrospinning is preferred for the nanosize fibers but this technic presents some drawbacks such as the requirement for a high voltage electrical field, a low production rate and the requirement for precise solution conductivity.
- Forcespinning is a method where a spinneret is rotated at high speed. Centrifugal force and hydrostatic pressure are combined to eject jets of liquid material through orifices. As a jet spray of material exits an orifice, the aerodynamic environment and the inertial force of the rotating spinneret stretch the material into a nanoscale fiber.
- polymeric nanofibers especially from polyolefin, such as polyethylene and polypropylene having good mechanical properties.
- the present invention provides the solution to one or more of the aforementioned needs.
- a process for the preparation of polyolefin fibers having mean fiber diameters of less than 5000 nm comprising the steps of:
- a fiber producing device comprising a body configured to receive said polyolefin solution, said body comprising one or more openings, and c) rotating the fiber producing device, wherein rotation of the fiber producing device causes the polyolefin solution to be passed through said one or more openings to produce polyolefin fibers having mean fiber diameters of less than 5000 nm,
- polyolefin is selected from the group comprising polyethylene polymers and copolymers having a weight average molecular weight M w of at least 40 000 daltons, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons.
- the present invention provides a process for the preparation of polyolefin fibers having mean fiber diameters of less than 5000 nm, said process comprising the steps of: a) preparing a polyolefin solution in a solvent,
- a fiber producing device comprising a body configured to receive said polyolefin solution, said body comprising one or more openings, and c) rotating the fiber producing device, wherein rotation of the fiber producing device causes the polyolefin solution to be passed through said one or more openings to produce polyolefin fibers having mean fiber diameters of less than 5000 nm,
- polyolefin is selected from the group comprising polyethylene polymers and copolymers having a weight average molecular weight M w of at least 40 000 daltons, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons;
- said fiber producing device is rotated at a speed of at least 10 000 revolutions per minute (RPM).
- the present invention also encompasses polyolefin fibers having mean fiber diameters of less than 5000 nm obtained by the process according to the first aspect of the invention.
- the present invention also encompasses polyolefin fibers having mean fiber diameters of less than 5000 nm, wherein said polyolefin is selected from the group comprising polyethylene polymers and copolymers having a weight average molecular weight Mw of at least 40 000 daltons, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons.
- the present invention also encompasses articles comprising the polyolefin fibers according to the second or third aspect of the invention, or prepared according to the process according to the first aspect of the invention.
- the process of the invention allows the manufacturing of polyolefin fibers having mean fiber diameters of less than 5000 nm, and improved mechanical properties (tensile strength, modulus and tenacity).
- Figure 1 represents a cross section schematic view of a fiber producing device as used in Examples 1 and 2.
- a fiber producing device comprising a body configured to receive said polyolefin solution, said body comprising one or more openings, and
- polyolefin is selected from the group comprising polyethylene polymers and copolymers having a weight average molecular weight M w of at least 40 000 daltons, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons.
- a process for the preparation of polyolefin fibers having mean fiber diameters of less than 5000 nm comprising the steps of:
- a fiber producing device comprising a body configured to receive said polyolefin solution, said body comprising one or more openings, and
- polyolefin is selected from the group comprising polyethylene polymers and copolymers having a weight average molecular weight M w of at least 40 000 daltons, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons;
- said fiber producing device is rotated at a speed of at least 10 000 RPM.
- polyolefin is selected from the group comprising polyethylene polymers and copolymers, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons.
- said polyolefin is selected from the group comprising polyethylene polymers and copolymers, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 200 000 daltons, preferably at least 300 000 daltons, preferably at least 400 000 daltons, preferably at least 500 000 daltons, preferably at least 600 000 daltons, preferably at least 700 000 daltons, preferably at least 800 000 daltons, preferably at least 900 000 daltons, preferably at least 1 000 000 daltons.
- the polyolefin solution comprises at least 1 % and at most 50 % by weight of the polyolefin based on the total weight of the polyolefin solution, preferably at least 5 % and at most 20 % by weight.
- said solvent is selected from the group comprising C6-C16 alcohols, fully saturated white mineral oil, vegetable oils, C4-C20 carboxylic acids, aliphatic and alicyclic hydrocarbons, petroleum fractions, mineral oil, kerosene, aromatic hydrocarbons including hydrogenated derivatives thereof, halogenated hydrocarbons, cycloalkanes, cycloalkenes, and terpenes.
- Polyolefin fibers having mean fiber diameters of less than 5000 nm obtained by the process according to any one of statements 1 to 20.
- Polyolefin fibers having mean fiber diameters of less than 5000 nm wherein said polyolefin is selected from the group comprising polyethylene polymers and copolymers having a weight average molecular weight Mw of at least 40 000 daltons, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons.
- polyolefin fibers according to statement 21 having mean fiber diameters of less than 5000 nm, wherein said polyolefin is selected from the group comprising polyethylene polymers and copolymers having a weight average molecular weight Mw of at least 40 000 daltons, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons.
- polyolefin fibers according to any one of statements 21 to 23, in the form of a nonwoven web.
- polyolefin fibers according to any one of statements 21 to 30, wherein the polyolefin is UHMWPE.
- fiber generally refers to an elongate structure that either has a definite length or is substantially continuous in nature.
- nanofibers refers to fibers having a number average diameter (or similar cross-sectional dimension for non-circular shapes) of less than about 1000 nm. In the case of non-round cross-sectional nanofibers, the term “diameter” as used herein refers to the greatest cross-sectional dimension.
- the present invention employs a fiber forming device that uses centrifugal spinning techniques, also referred herein as force spinning techniques.
- the fibers are formed by a process that includes the ejection of a polyolefin solution from a fiber forming device that comprises a body (e.g., a spinneret or spin disc) that propels the polymer solution by centrifugal force into the form of fibers.
- a body e.g., a spinneret or spin disc
- the polyolefin fibers can be produced using forcespinning of the polyolefin solution through one or more openings provided in the body.
- the present process comprises the steps of:
- a fiber producing device comprising a body configured to receive said polyolefin solution, said body comprising one or more openings, and c) rotating the fiber producing device, wherein rotation of the fiber producing device causes the polyolefin solution to be passed through the one or more openings to produce polyolefin fibers having mean fiber diameters of less than 5000 nm,
- said polyolefin is selected from the group comprising polyethylene polymers and copolymers having a weight average molecular weight M w of at least 40 000 daltons, and polypropylene polymers and copolymers, having a weight average molecular weight Mw of at least 120 000 daltons.
- said fiber producing device is rotated at a speed of at least 10 000 RPM.
- the polyethylene suitable for use in the present invention may be any ethylene homopolymer or any copolymer of ethylene and one or more comonomers having a weight average molecular weight M w of at least 40 000 daltons.
- the comonomer is different from ethylene and chosen such that it is suited for copolymerization with the olefin.
- the comonomer may be a C3-C20 alpha-olefin, such as propylene, 1 -butene, 1 -pentene, 1 - hexene, 4-methyl-1 -pentene, 1 -octene, 1 -decene, 1 -dodecene, 1 -tetradecene, 1 - hexadecene, 1 -octadecene or 1 -eicosene.
- said polyethylene is a homopolymer.
- polyethylene polymers and copolymers for use in the present invention can have a melt flow index MI2 of at most 34 g/10 min as measured according to ISO 1 133 Procedure B, condition D at a temperature of 190°C and a load of 2.16 kg, for example at most 30 g/10min, preferably at most 20 g/10min, preferably at most 10 g/10min, preferably at most 1 g/10min, preferably at most 0.1 g/10min.
- Polyethylene polymers and copolymers for use in the invention can be produced by polymerizing ethylene and optionally one or more comonomers, such as ethylene, in the presence of a catalyst system and optionally in the presence of hydrogen.
- a catalyst system and optionally in the presence of hydrogen.
- the term "catalyst" refers to a substance that causes a change in the rate of a polymerization reaction. In the present invention, it is especially applicable to catalysts suitable for the polymerization of propylene to polypropylene.
- the catalyst can be a chromium, a Ziegler-Natta or a metallocene catalyst system. In a preferred embodiment, said catalyst is a Ziegler-Natta catalyst.
- the polyethylene polymers used herein is a homopolymer, preferably a homopolymer with a low long chain branching content.
- the polyethylene is ultra-high molecular weight polyethylene (UHMWPE) having a molecular weight distribution of at most 10; preferably the UHMWPE has a molecular weight distribution of at least 5; preferably the UHMWPE has a molecular weight distribution of at least 5 and of at most 10; preferably, the UHMWPE has a molecular weight distribution of at least 5 and of at most 9; UHMWPE has a molecular weight distribution of at least 6 and of at most 9.
- UHMWPE ultra-high molecular weight polyethylene
- the polypropylene suitable for use in the present invention may be any propylene homopolymer or any copolymer of propylene and one or more comonomers, having a weight average molecular weight Mw of at least 120 000 daltons.
- the polypropylene can be a random copolymer.
- the one or more comonomers are preferably selected from the group consisting of ethylene and C4-C10 alpha-olefins, such as for example 1 -butene, 1 -pentene, 1 -hexene, 1-octene, or 4-methyl-1 -pentene.
- Ethylene and 1 -butene are the preferred comonomers.
- Ethylene is the most preferred comonomer.
- the polypropylene can be a propylene homopolymer.
- the polypropylene polymers and copolymers can have a melt flow index of at most 32 g/10 min as measured according to ISO 1 133, condition M, at 230°C and under a load of 2.16 kg, for example at most 30 g/10min, preferably at most 20 g/10min, preferably at most 10 g/10min, preferably at most 1 g/10min, preferably at most 0.1 g/10min.
- the polypropylene polymers and copolymers for use in the present invention can be produced by polymerizing propylene and optionally one or more co-monomers, such as ethylene, in the presence of a catalyst system and optionally in the presence of hydrogen.
- the catalyst can be a chromium, a Ziegler-Natta or a metallocene catalyst system.
- the polyethylene or polypropylene polymers used in the process of the invention is ultra-high molecular weight (UHMW), i.e. having an intrinsic viscosity (IV) as measured on solution in decalin (decahydronaphthalene) at 135°C, according to ISO 1628-3, of at least 5 dl/g, preferably at least 10 dl/g, more preferably at least 15 dl/g.
- the IV is at most 40 dl/g, more preferably at most 30 dl/g.
- the UHMW polyolefin solution is preferably prepared with a concentration of at least 1 % by weight.
- the UHMW polyolefin solution preferably, has a concentration of at most 50 % by weight, more preferably at most 30 % by weight, even more preferably at most 25 % by weight, most preferably at most 20 % by weight.
- any of the known solvents suitable for forming a polyolefin gel may be used.
- said solvent can be selected from the group comprising C6-C16 alcohols; fully saturated white mineral oil; vegetable oils, such as vegetable oil selected from the group comprising olive oil, peanut oil, palm oil, and coconut oil; C4-C20 carboxylic acids, such as C4-C20 carboxylic acids selected from the group comprising butanoic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic acid, nonanoic acid, decanoic acid, undecanoic acid, dodecanoic acid, tridecanoic acid, tetradecanoic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, octadecanoic acid, nonadecanoic acid, and eicosanoic acid;
- the solvent of choice is white mineral oil, paraffins, decalin, nonan-2-ol (CAS 628-99-9), C9-C1 1 alcohols such as (CAS 66455-17-2) or C10-16 alcohols such as (CAS 67762-41 -8).
- the crystallization temperature when analyzing the solution (gel) by DSC in comparison with the analysis of the pure polymer, the crystallization temperature must decreased by at least 1 °C. To determine such crystallization temperature decrease, the following procedure is used:
- a polymer sample (between 2 and 10 mg) is introduced in the DSC apparatus (e.g. DSC1 of Mettler Toledo).
- DSC apparatus e.g. DSC1 of Mettler Toledo.
- the following thermal history is imposed: stabilization of the sample at 20°C during 4 minutes, heating at 20°C/min up to 220°C, stabilization at 220°C during 3 minutes, cooling at -20°C/min up to -20°C, stabilization of the sample at 20°C during 3 minutes and heating at 20°C/min up to 220°C.
- the crystallization temperature is determined during the above described cooling step. After substraction of the baseline (a linear line drawn between the onset of the crystallization peak, so close to 130°C, and 20°C), the crystallization temperature is assimilated to the temperature of the extreme of the peak;
- Step b) of the present process comprises placing said polyolefin solution in a fiber producing device comprising a body configured to receive said polyolefin solution, said body comprising one or more openings, and step c) comprises rotating the fiber producing device, wherein rotation of the fiber producing device causes the polyolefin solution to be passed through the one or more openings to produce polyolefin fibers having mean fiber diameters of less than 5000 nm.
- the fiber forming device can include a spinneret having a reservoir configured to contain the polyolefin solution.
- the spinneret is rotated centrifugally on an axis at high revolutions per minute creating hydrostatic and centrifugal forces.
- the hydrostatic and centrifugal forces push the solution to an outer wall having at least one opening (orifice) located therein.
- the polyolefin solution enters the one or more openings and is released therefrom.
- the centrifugal and hydrostatic forces combine to initiate a jet of the solution that impinges against a fiber collector to produce the fibers.
- the polyolefin solution is ejected as a jet of material from one or more openings (orifices) into the surrounding atmosphere.
- the one or more openings and associated channel feeding can be configured with a size and shape to cause a fine jet of the solution to form on exit from the openings.
- an opening means an exit orifice plus any associated channel or passage feeding the opening and serving to define the nature of the expelled jet of fiber-forming solution.
- These openings may be of a variety of shapes (e.g., circular, elliptical, rectangular, square) and of a variety of diameter sizes. When multiple openings are employed, not every opening need to be identical to another opening, but in certain embodiments, every opening is of the same configuration.
- each opening has a diameter of at most 2 mm, preferably at most 1 mm, yet more preferably at most 0.5 mm, for example at most 0.1 mm.
- the diameter of the opening is herein meant to be the effective diameter, i.e. for non-circular or irregularly shaped openings, the largest distance between the outer boundaries of the openings.
- the ejected material can solidify as a superfine fiber that has a diameter significantly less than the inner diameter of the outlet port.
- the fiber producing device may rotate at a speed of, for example, at least 10 000 revolutions per minute (RPM), in some embodiments it is at least 15 000 RPM. In other embodiments, it is at least 20 000 RPM. In other embodiments, it is at least 22 000 RPM.
- RPM revolutions per minute
- the speed of the fiber producing device may be fixed while the fiber producing device is spinning, or may be adjusted while the fiber producing device is spinning.
- the temperature of the rotating body may also be controlled during fiber spinning.
- the rotating body temperature may range from about 40°C, preferably from about 100°C to about 200°C.
- the fibers are distributed radially away from the rotating member onto a collection surface.
- collecting of fibers refers to fibers coming to rest against a fiber collection device or collector. After the fibers are collected, the fibers may be removed from a fiber collection device by a human, robot, a conveyor belt, by gravity or other technics. A variety of methods and fiber (e.g., nanofiber) collection devices may be used to collect fibers.
- the fibers could be ejected from the spinneret onto a surface disposed below the spinneret or on a wall across from outlet ports on the spinneret.
- the collection surface may vary as desired, and can be either stationary or rotated during collection of the fibers.
- the collection surface may be provided on a collection wall that surrounds the rotating member.
- the collected fiber material can form a web of two- or three-dimensional entangled fibers that can be worked to a desired surface area and thickness, depending on the amount of time fibers continue to be expelled onto a collector, and control over the surface area of the collector.
- the polyolefin fibers are then cooled.
- the temperature to which the polyolefin fibers are cooled is at most 100°C, more preferably at most 80°C, most preferably at most 60°C.
- the temperature to which the polyolefin fibers are cooled is at least 1 °C, more preferably at least 5°C, even more preferably at least 10°C, most preferably at least 15°C.
- the solvent may be removed from the fibers during and/or after spinning.
- the fibers (or a web containing the fibers) may simply be washed, dried and/or heated to remove the solvent.
- the solvent may therefore be removed by evaporation, washing or any other technics.
- said polyolefin fibers can be subjected to a solvent removal step wherein the solvent is at least partly removed from the polyolefin fibers to form solid polyolefin fibers.
- the solvent removal process may be performed by known methods, for example by evaporation when a relatively volatile solvent, e.g. decaline, is used to prepare the polyolefin solution or by using an extraction liquid like cyclohexane, e.g. when mineral oils are used, or by a combination of both methods.
- a relatively volatile solvent e.g. decaline
- an extraction liquid like cyclohexane, e.g. when mineral oils are used, or by a combination of both methods.
- Suitable extraction liquids are solvent dependent.
- the extraction liquid is chosen such that the solvent can be separated from the extraction liquid for recycling.
- the residual solvent left in the polyolefin fiber of the invention is removed by placing said fiber in a vacuumed oven at a temperature of preferably at most 148°C, more preferably of at most 145°C, most preferably of at most 135°C.
- the oven is kept at a temperature of at least 20°C, more preferably of at least 50°C. More preferably, the removal of the residual solvent is carried out while keeping the fiber taut, i.e. the fiber is prevented from slackening.
- the amount of residual solvent, left in the solid polyolefin fibers after the extraction step may vary within large limits but lowest amount of residuals solvent are preferred.
- the residual solvent is, in a mass percent, of at most 15 % of the initial amount of solvent in the polyolefin solution, more preferably in a mass percent of at most 10 %, most preferably in a mass percent of at most 5 %, even more preferably in a mass percent of at most 1 %.
- the polyolefin fiber at the end of the solvent removal step comprises solvent in an amount below 800 ppm by mass. More preferably said amount of the solvent is below 600 ppm, even more preferably below 300 ppm, most preferably below 100 ppm by mass.
- the fibers that are collected are continuous, discontinuous, mat, woven, nonwoven or a mixture of these configurations.
- the fibers may be formed into two- or three-dimensional webs, i.e., mats, films or membranes.
- the fibers produced using any of the devices and methods described herein may be used in a variety of applications.
- Some general fields of use include, but are not limited to: food, materials, electrical, defense, tissue engineering, biotechnology, medical devices, energy, alternative energy (e.g., solar, wind, nuclear, and hydroelectric energy), therapeutic medicine, drug delivery (e.g., drug solubility improvement, drug encapsulation, etc.), textiles/fabrics, nonwoven materials, filtration (e.g., air, water, fuel, semiconductor, biomedical, etc.), automotive, sports, aeronautics, space, energy transmission, papers, substrates, hygiene, cosmetics, construction, apparel, packaging, geotextiles, thermal and acoustic insulation.
- Some products that may be formed using the polyolefin fibers include but are not limited to: filters; wound dressings; cell growth substrates or scaffolds; battery separators; sutures; chemical sensors; textiles/fabrics that are water & stain resistant, odor resistant, insulating, self-cleaning, penetration resistant, anti-microbial, porous/breathing, tear resistant, and wear resistant; force energy absorbing for personal body protection armor; construction reinforcement materials; tissue engineering substrates; tissue engineering Petri dishes; filters used in pharmaceutical manufacturing; filters for deep filter functionality; hydrophobic materials such as textiles; building products that enhance durability, flexibility, air tightness; adhesives; tapes; epoxies; glues; adsorptive materials; diaper media; mattress covers; acoustic materials; and liquid, gas, chemical, or air filters.
- the present process has the advantage of not having the usual drawbacks of electrospinning. For instance, there is less constraint on the solvent used as the polar aspect of the gel is not necessarily required. Polyolefin fibers having mean fiber diameters of less than 5000 nm are obtained.
- Examples of mechanical properties construed in the light of the present invention are tensile strength, elastic modulus, breaking force, elongation at break and the like.
- the molecular weights can be determined by size exclusion chromatography (SEC) and in particular by gel permeation chromatography (GPC). Briefly, a GPC-IR5 from Polymer Char is used: 10 mg polyethylene sample is dissolved at 160°C in 10 ml of trichlorobenzene for 1 hour. Injection volume: about 400 ⁇ , automatic sample preparation and injection temperature: 160°C. Column temperature: 145°C. Detector temperature: 160°C.
- M n number average
- M w weight average
- M z z average
- N, and W are the number and weight, respectively, of molecules having molecular weight Mi.
- the third representation in each case defines how one obtains these averages from SEC chromatograms.
- h is the height (from baseline) of the SEC curve at the i th elution fraction
- M is the molecular weight of species eluting at this increment.
- UHMWPE UHMWPE
- the molecular weight distribution was measured from the quantification of the transition zone between the Newtonian viscosity and the power-law domain. Such transition is known to be related to both the molecular weight distribution and to the long chain branching content in the polymer. As the long chain branching content in the polyethylene grade used in the example (UHMWPE GUR® 41 13) is zero or at least very low, such transition can be related to the molecular weight distribution.
- Optical microscopy determination of the fiber diameter 5 fiber segments were fixed on a flat glass and introduced in a Leica DMLP microscope, connected to a JVC camera. A "X40" lens was used. Images of the 5 fibers were then registered and analyzed using the IM500 software from Leica: the fiber diameter was determined by comparison with the image of a reference (the image of a certificated graduated glass previously recorded using the same lens). The reported diameter was the average value of the 5 determinations. For SEM microscopy measurement, a small bundle containing several fibres was vertically introduced in a capsule and embedded into an epoxy resin.
- the bundle+epoxy sample was cut (using a milling machine equipped with a diamond) in a direction transverse to the fibre axis. Doing so, a surface was available, which was treated (metallization) with carbon.
- Figure 1 represents a cross section schematic view of a fiber producing device as used in Examples 1 and 2.
- the fiber producing device comprises a spinneret 1 .
- the spinneret 1 was mechanically coupled to a motor 2, which rotates the spinneret 1 in a circular motion via a shaft 5.
- the speed of the motor 2 is adjustable by increment of 2 000 RPM from 10 000 to 22 000 RPM.
- the motor 2 was fixed on a strong frame 3, a circular collector 4 of 56 cm diameter was centered from the axis of the spinneret 1 .
- the spinneret 1 comprised a stainless steel cell 7 closed with a screwed lid 6. In the bottom of the cell 7, two orifices diametrically opposite were equipped of screws with calibrated bore 8 of 0.5 mm diameter.
- the shaft 5 was screwed on the top of the lid 6 to allow attachment at the mandrel of the motor 2.
- the external dimensions of the cell 7 were 29.96 mm diameter and 35.40 mm height.
- the internal dimensions of the cell 7 were 20.80 mm diameter and 1 1 .13 mm height.
- Mean measured diameter of the produced fibers was 3.5 ⁇ .
Abstract
Description
Claims
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/736,176 US20180187336A1 (en) | 2015-06-15 | 2016-06-14 | Process for the Preparation of Polyolefin Fibers |
CA2988235A CA2988235A1 (en) | 2015-06-15 | 2016-06-14 | Process for the preparation of polyolefin fibers |
JP2017564694A JP2018517861A (en) | 2015-06-15 | 2016-06-14 | Method for producing polyolefin fiber |
EP16730341.1A EP3307928A1 (en) | 2015-06-15 | 2016-06-14 | Process for the preparation of polyolefin fibers |
CN201680035093.9A CN107750285A (en) | 2015-06-15 | 2016-06-14 | For the technique for preparing polyolefine fiber |
KR1020187001113A KR20180016595A (en) | 2015-06-15 | 2016-06-14 | Process for the preparation of polyolefin fibers |
BR112017026817A BR112017026817A2 (en) | 2015-06-15 | 2016-06-14 | process for preparing polyolefin fibers |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP15172167.7 | 2015-06-15 | ||
EP15172167 | 2015-06-15 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2016202813A1 true WO2016202813A1 (en) | 2016-12-22 |
Family
ID=53397959
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2016/063661 WO2016202813A1 (en) | 2015-06-15 | 2016-06-14 | Process for the preparation of polyolefin fibers |
Country Status (8)
Country | Link |
---|---|
US (1) | US20180187336A1 (en) |
EP (1) | EP3307928A1 (en) |
JP (1) | JP2018517861A (en) |
KR (1) | KR20180016595A (en) |
CN (1) | CN107750285A (en) |
BR (1) | BR112017026817A2 (en) |
CA (1) | CA2988235A1 (en) |
WO (1) | WO2016202813A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2018191291A1 (en) * | 2017-04-10 | 2018-10-18 | Other Lab, Llc | Coiled actuator system and method |
JP2019031755A (en) * | 2017-08-07 | 2019-02-28 | 国立大学法人群馬大学 | High strength fiber, and method for producing high strength fiber |
US10793981B2 (en) | 2015-05-21 | 2020-10-06 | Other Lab, Llc | System and method for thermally adaptive materials |
US11885577B2 (en) | 2015-05-20 | 2024-01-30 | Other Lab, Llc | Heat exchanger array system and method for an air thermal conditioner |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11781006B2 (en) * | 2018-01-21 | 2023-10-10 | Sebastian S. Plamthottam | Gel spun fibers and method of making |
US20220205645A1 (en) * | 2020-12-28 | 2022-06-30 | Koninklijke Fabriek Inventum B.V. | Hydrophobic filter in oven air oulet |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1373708A (en) * | 1971-11-26 | 1974-11-13 | Gulf Research Development Co | Fibril process |
GB1387233A (en) * | 1972-03-20 | 1975-03-12 | Gulf Research Development Co | Fibril formation process |
US20140353859A1 (en) * | 2011-02-07 | 2014-12-04 | Fiberio Technology Corporation | Methods for the production of microfibers and nanofibers using a multiple chamber fiber producing device |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2271796A4 (en) * | 2008-03-17 | 2012-01-04 | Univ Texas | Superfine fiber creating spinneret and uses thereof |
WO2013157160A1 (en) * | 2012-04-18 | 2013-10-24 | テックワン株式会社 | Carbon-fiber material, method for manufacturing carbon-fiber material, and material having carbon-fiber material |
US20140012304A1 (en) * | 2012-07-03 | 2014-01-09 | Merit Medical Systems, Inc. | Multilayered balloon |
ES2685963T3 (en) * | 2014-03-18 | 2018-10-15 | Tepha, Inc. | Microfiber bands of poly-4-hydroxybutyrate and their copolymers produced by centrifugal spinning |
-
2016
- 2016-06-14 JP JP2017564694A patent/JP2018517861A/en not_active Abandoned
- 2016-06-14 WO PCT/EP2016/063661 patent/WO2016202813A1/en active Application Filing
- 2016-06-14 BR BR112017026817A patent/BR112017026817A2/en not_active Application Discontinuation
- 2016-06-14 CN CN201680035093.9A patent/CN107750285A/en active Pending
- 2016-06-14 CA CA2988235A patent/CA2988235A1/en not_active Abandoned
- 2016-06-14 EP EP16730341.1A patent/EP3307928A1/en not_active Withdrawn
- 2016-06-14 KR KR1020187001113A patent/KR20180016595A/en unknown
- 2016-06-14 US US15/736,176 patent/US20180187336A1/en not_active Abandoned
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1373708A (en) * | 1971-11-26 | 1974-11-13 | Gulf Research Development Co | Fibril process |
GB1387233A (en) * | 1972-03-20 | 1975-03-12 | Gulf Research Development Co | Fibril formation process |
US20140353859A1 (en) * | 2011-02-07 | 2014-12-04 | Fiberio Technology Corporation | Methods for the production of microfibers and nanofibers using a multiple chamber fiber producing device |
Non-Patent Citations (1)
Title |
---|
XIA LEI ET AL: "A comparative study of UHMWPE fibers prepared by flash-spinning and gel-spinning", MATERIALS LETTERS, vol. 147, 18 February 2015 (2015-02-18), pages 79 - 81, XP029204077, ISSN: 0167-577X, DOI: 10.1016/J.MATLET.2015.02.046 * |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11885577B2 (en) | 2015-05-20 | 2024-01-30 | Other Lab, Llc | Heat exchanger array system and method for an air thermal conditioner |
US10793981B2 (en) | 2015-05-21 | 2020-10-06 | Other Lab, Llc | System and method for thermally adaptive materials |
US11686024B2 (en) | 2015-05-21 | 2023-06-27 | Other Lab, Llc | System and method for thermally adaptive materials |
WO2018191291A1 (en) * | 2017-04-10 | 2018-10-18 | Other Lab, Llc | Coiled actuator system and method |
US10793979B2 (en) | 2017-04-10 | 2020-10-06 | Other Lab, Llc | Coiled actuator system and method |
US11519106B2 (en) | 2017-04-10 | 2022-12-06 | Other Lab, Llc | Coiled actuator system and method |
JP2019031755A (en) * | 2017-08-07 | 2019-02-28 | 国立大学法人群馬大学 | High strength fiber, and method for producing high strength fiber |
JP7014354B2 (en) | 2017-08-07 | 2022-02-01 | 国立大学法人群馬大学 | High-strength fiber and method for manufacturing high-strength fiber |
Also Published As
Publication number | Publication date |
---|---|
EP3307928A1 (en) | 2018-04-18 |
JP2018517861A (en) | 2018-07-05 |
KR20180016595A (en) | 2018-02-14 |
CN107750285A (en) | 2018-03-02 |
CA2988235A1 (en) | 2016-12-22 |
BR112017026817A2 (en) | 2018-08-14 |
US20180187336A1 (en) | 2018-07-05 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20180187336A1 (en) | Process for the Preparation of Polyolefin Fibers | |
JP5231019B2 (en) | Flash spun web containing submicron filaments and method of forming the same | |
KR101709467B1 (en) | Polypropylene Fibers and Fabrics | |
KR101519169B1 (en) | Production of nanofibers by melt spinning | |
WO2005061773A1 (en) | Polyethylene-based, soft nonwoven fabric | |
US20110183568A1 (en) | Fibers and nonwovens with increased surface roughness | |
WO2009058477A1 (en) | Polypropylene spunbond fibers | |
KR100408353B1 (en) | Process for producing fibers for high strength non-woven materials, and the resulting fibers and non-wovens | |
EP2563955A2 (en) | Process and product of high strength uhmw pe fibers | |
US10590565B2 (en) | Polymeric nanofibers and nanofibrous web | |
Hosseini Ravandi et al. | Mechanical properties and morphology of hot drawn polyacrylonitrile nanofibrous yarn | |
WO2017123293A2 (en) | Gel-electrospinning process for preparing high performance polymer nanofibers | |
Qiang et al. | Effect of ultrasonic vibration on structure and performance of electrospun PAN fibrous membrane | |
CA3056171A1 (en) | Polypropylene composition with improved tensile properties, fibers and nonwoven structures | |
Singh et al. | Effect of process parameters on the microstructural characteristics of electrospun poly (vinyl alcohol) fiber mats | |
CN109196148A (en) | Polypropylene system stretches fiber | |
EP3202843A1 (en) | Polyolefin-based compositions, fibers, and related multi-layered structures prepared therefrom | |
Kim et al. | Electrical and mechanical properties of poly (vinylidene fluoride) nanofibrillar materials | |
Fink | Polyethylene Fiber Extrusion | |
CN116783235A (en) | High crystalline olefin polymers for high speed spinning | |
Drábek | Aplikovaná reologie pro výrobu polymerních nanovláken |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 16730341 Country of ref document: EP Kind code of ref document: A1 |
|
ENP | Entry into the national phase |
Ref document number: 2988235 Country of ref document: CA |
|
ENP | Entry into the national phase |
Ref document number: 2017564694 Country of ref document: JP Kind code of ref document: A |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
ENP | Entry into the national phase |
Ref document number: 20187001113 Country of ref document: KR Kind code of ref document: A |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2016730341 Country of ref document: EP |
|
REG | Reference to national code |
Ref country code: BR Ref legal event code: B01A Ref document number: 112017026817 Country of ref document: BR |
|
ENP | Entry into the national phase |
Ref document number: 112017026817 Country of ref document: BR Kind code of ref document: A2 Effective date: 20171212 |