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Techinque for forming porous fibers

A fibrous, nanoporous technology used in extruders to melt and draw thermoplastic compositions in order to form a porous network therein. In the field of twin-screw extrusion, it can solve problems such as large chamber size, reduced melt strength, breakage, etc.

Active Publication Date: 2019-10-11
KIMBERLY-CLARK WORLDWIDE INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Furthermore, typical foaming methods yield large cell sizes, such as greater than 100 μm
This reduces melt strength, leading to fractures during high-speed production processes with high deformation rates (e.g. fiber spinning, film forming, molding, etc.)

Method used

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  • Techinque for forming porous fibers
  • Techinque for forming porous fibers
  • Techinque for forming porous fibers

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0127] Blend of 93% by weight semi-crystalline polyethylene terephthalate (Eastlon PET CFF-A17 from Far Eastern New Century Corporation) and 7% by weight polyester-polyether copolymer (Hytrel RS 40FSNC010, DuPont). Both the polyester and the polyester-polyether copolymer were dry blended and then fed into a twin screw extruder. The polymer was fed to a co-rotating twin-screw extruder for compounding (ZSK-30, 30 mm diameter, 1328 mm length), manufactured by Werner and Pfieiderer Corporation of Ramsey, New Jersey. The extruder had 14 zones, numbered 1-14 from the feed hopper to the die. The first drum zone #1 received resin via a gravity feeder at a total throughput of 20 pounds per hour. The die used to extrude the resin had 3 die openings (6 mm diameter) spaced 4 mm apart. Once formed, the extruded resin was cooled on a fan-cooled conveyor belt and passed through a Conair pelletizer to form pellets. The extruder screw speed was 200 revolutions per minute ("rpm"). The pelle...

Embodiment 2

[0129] The resin blend from Example 1 was spun into a monocomponent fiber tow containing 144 filaments which was separated into two bundles of 72 fiber tows by a spinneret having a diameter of 0.3 mm. The extrusion temperature was 300 °C and the throughput was 0.96 ghm. The tow was drawn at 2500 mpm to give a total tow denier of 261 g / 9000 meters.

Embodiment 3

[0131] The tow was formed as in Example 2, except that the take-up speed was 3000 meters per minute, resulting in a denier of 212 g / 9000 meters.

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Abstract

A method for forming a fiber is provided. The method comprises extruding a matrix polymer and a nanoinclusion additive to form a thermoplastic composition in which the nanoinclusion additive is dispersed within a continuous phase of the matrix polymer. The extruded thermoplastic composition is thereafter passed through a spinneret to form a fiber having a porous network containing a plurality of nanopores, wherein the average percent volume occupied by the nanopores within a given unit volume of the fiber is from about 3% to about 15% per cm3.

Description

Background technique [0001] Significant efforts have been made to produce low density fibers to improve the use of natural resources and the reduction of carbon emissions in finished products. A typical method of producing such low density fibers is to use physical or chemical blowing agents to foam the polymer, this foaming creating air-filled pores through the body. Chemical blowing agents are compounds that undergo a chemical reaction that releases a gas that passes through the bulk of the polymer to create a pore structure. Physical blowing agents are typically compressed gases dispersed in a polymer and expanded to create cells. Regardless, typical foaming methods result in low molecular orientation because cell formation occurs while the polymer is in the molten state. This prevents the polymer from strain hardening, which typically occurs at temperatures well above the polymer's melting temperature or glass transition temperature, resulting in a product with low mecha...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): D04H1/4282D04H13/00A61F13/514A61F13/511A61F13/15
CPCA61F13/51D04H1/42D04H3/005A61F2013/51023D01F1/08D01D5/247D01F6/04D01F6/62D01F1/02D04H1/4282D04H13/00A61F13/51401A61F13/51121A61F13/15617D01H1/40A61L15/26C08L67/02C08L2203/12C08L2205/025D10B2509/026D10B2401/10D10B2321/021D10B2321/02D10B2331/04
Inventor R·J·麦克尼尼V·A·托波尔卡雷夫徐岳文
Owner KIMBERLY-CLARK WORLDWIDE INC