Amine-Modified Polymer Flame Resistant Fiber Production
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Solution Overview
Problem
Current methods for producing flame-resistant fibers and carbon fibers face challenges such as inefficient processing, high costs, corrosion issues, and trade-offs between mechanical strength, compressive strength, and electrical conductivity due to limitations in molecular orientation and crystal size.
Innovation Solution
A flame-resistant fiber is developed using an amine-modified polymer with high molecular orientation and specific gravity, produced through wet or semi-dry spinning followed by controlled heat treatment, which allows for high-performance carbon fiber production with improved mechanical and electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air treatment method is used to make flame resistant, then flame retardancy is achieved, but processing time is excessively long and fiber thickness is limited
Solution Approach 1:
The invention changes the fundamental parameter of the treatment environment from gas phase (air) to liquid phase (solvent system). By dissolving the polymer in a solvent and performing cyclization in solution, the reaction efficiency is dramatically improved, reducing processing time while maintaining flame retardancy. This phase transition from gas to liquid enables better heat and mass transfer, solving the productivity issue.
Solution Approach 2:
The invention introduces a solvent as an intermediary medium to facilitate the cyclization reaction. The solvent acts as a heat transfer medium and reaction medium, enabling controlled exothermic reaction and improving processing efficiency. This intermediary allows the reaction to proceed uniformly throughout the fiber cross-section without the thickness limitations of air treatment.
2Ease of manufacture
If strongly acidic solvent is used to dissolve polymer powder, then solution can be formed, but apparatus corrosion resistance is required and cost increases
Solution Approach 1:
The invention changes the chemical parameter of the solvent from strongly acidic to non-acidic or weakly acidic. By selecting solvents such as N-methyl-2-pyrrolidone, dimethyl sulfoxide, or other polar aprotic solvents, the polymer can be dissolved without requiring corrosion-resistant apparatus. This parameter change maintains solution formation capability while eliminating the need for special materials.
3Reliability
If dilute polymer solution is used for cyclization, then polymer can be converted to flame resistant structure, but viscosity is too low for fiber formation
Solution Approach 1:
The invention performs preliminary cyclization conversion in the solution state before fiber formation. By first converting the polymer to its flame-resistant cyclized structure in solution, and then proceeding to fiber formation through spinning or extrusion, the process avoids the viscosity problem. The preliminary action of cyclization in solution enables subsequent easy fiber formation with high molecular orientation.
Solution Approach 2:
The invention separates the cyclization reaction and fiber formation into distinct dimensional stages. Cyclization occurs in the molecular dimension in solution, while fiber formation occurs in the macroscopic dimension through spinning. This dimensional separation allows independent optimization of each process, achieving both complete cyclization conversion and good fiber forming ability.
4Strength
If high molecular orientation is achieved in flame resistant fiber, then carbon fiber mechanical properties improve, but production process complexity increases
Solution Approach 1:
The invention performs preliminary molecular orientation during the fiber formation process from the cyclized solution. By applying drawing or stretching during spinning or extrusion, high molecular orientation is achieved before carbonization. This preliminary orientation is maintained through the carbonization process, resulting in high mechanical properties without requiring complex post-processing steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method stabilizes fiber formation, enhances mechanical and electrical properties, and achieves compatibility between tensile modulus and compressive strength, resulting in a high-performance carbon fiber with novel characteristics.
Implementation Method 1
a polyacrylonitrile (hereunder, abbreviated as PAN) based flame resistant fiber is obtained by making a PAN-based precursor fiber flame resistant (cyclization reaction and oxidation reaction of PAN) at a high temperature of 200 to 300°C in the air
Implementation Method 2
a polyacrylonitrile (hereunder, abbreviated as PAN) based flame resistant fiber is obtained by making a PAN-based precursor fiber flame resistant (cyclization reaction and oxidation reaction of PAN) at a high temperature of 200 to 300°C in the air
Implementation Method 3
A flame-resistant fiber is developed using an amine-modified polymer with high molecular orientation and specific gravity, produced through wet or semi-dry spinning followed by controlled heat treatment
Implementation Method 4
produced through wet or semi-dry spinning followed by controlled heat treatment
Implementation Method 5
produced through wet or semi-dry spinning followed by controlled heat treatment
Implementation Method 6
Such a carbon fiber is generally obtained by a carbonization treatment of a flame resistant fiber by heating at a high temperature in an inert gas such as nitrogen
Data Source
Figure 1~2
AI summary
In a flame resistant fiber assembly obtainable by fiber forming a flame resistant polymer, a flame resistant fiber of a higher performance is obtained by improving fiber forming ability. A carbon fiber of a high performance is obtained by carbonizing the flame resistant fiber. At obtaining a flame resistant fiber by subjecting a solution containing a flame resistant polymer modified by an amine-based compound to a wet spinning or a semi-dry spinning in a coagulation bath in such a way that a degree of swelling of a coagulated yarn at the outlet of the coagulation bath is 100 to 1000 wt% and then, in a bath, subjecting to a drawing and/or water washing and to a drying under tension, the flame resistant fiber is produced by controlling temperature of the drawing bath/water washing bath, drying temperature or tension in such a way that the obtained fiber would not crystallize. And, a carbon fiber is produced by carbonizing said flame resistant fiber.