Para-aramid Composite Particles via Jet Spinning and Shear Coagulation
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Solution Overview
Problem
Aramid particles used in various applications face challenges such as additive retention issues during paper formation and pollution problems due to the use of chemicals, and existing methods often result in particles with low dry solid content and high water content, making them difficult to process and transport.
Innovation Solution
A method for producing para-aramid particles with improved properties by creating a polymer-additive composite through jet spinning or rotor-stator coagulation, where the aramid polymer is dissolved in a solvent with a solid additive, forming a stable dope that can be processed into fibrids, fibrils, or pulp with high additive content without the need for chemical retention aids, resulting in particles with enhanced physical properties and reduced water content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additive materials are added to aramid particles to adjust properties, then the functional properties of particles are improved, but additive retention problems occur during paper formation and chemical pollution increases
Solution Approach 1:
The invention merges the aramid polymer and additive materials into a single composite particle structure during the spinning process. The additive materials are incorporated into the polymer matrix, creating a unified composite particle where the additive is retained within the particle itself rather than being separate, which eliminates retention problems during paper formation and reduces chemical pollution.
Solution Approach 2:
The invention creates composite aramid particles by combining the aramid polymer with additive materials during the spinning process. The composite structure integrates the additive within the polymer matrix, allowing the additive to be permanently retained in the particle without requiring chemical retention aids during subsequent processing.
2Ease of manufacture
If conventional spinning methods are used to produce aramid particles, then the production process is simple, but the particles have low dry solid content and high water content making them difficult to process and transport
Solution Approach 1:
The invention changes the parameters of the spinning process by using a rotor-stator apparatus that applies shear forces to the dope during coagulation. This mechanical action removes excess water and increases the dry solid content of the resulting particles, transforming them from difficult-to-process wet material into easily transportable dry particles with improved handling characteristics.
3Reliability
If high additive content is added to improve particle properties, then the functional performance is enhanced, but clogging issues occur during processing
Solution Approach 1:
The invention performs preliminary dispersion of additive materials in the dope before spinning. The rotor-stator apparatus applies shear forces to thoroughly disperse and distribute the additive uniformly throughout the polymer solution before the spinning process, preventing aggregation and clogging during subsequent processing while maintaining high additive content for enhanced functional performance.
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 enables the production of aramid particles with higher dry solid content and improved adhesion, hardness, cut resistance, and color retention, simplifying the paper-making process and reducing pollution, while allowing for higher additive content without clogging issues, leading to more efficient and environmentally friendly production.
Implementation Method 1
jet spinning the dope to obtain a pulp, fibril or fibrid, wherein the dope comprises a solvent and 4 to 75 wt % of a composition consisting of 2 to 95 wt % of a para-aramid polymer and 5-98 wt % of a solid additive material
Implementation Method 2
coagulating the dope by means of a rotor-stator apparatus in which the polymer solution is applied through the stator on the rotor so that the precipitating polymer-additive composite particle is subjected to shear forces while they are in a plastic deformable stage
Implementation Method 3
coagulating the dope by means of a rotor-stator apparatus in which the polymer solution is applied through the stator on the rotor so that the precipitating polymer-additive composite particle
Data Source
AI summary
The invention pertains to a method for making a polymer-additive composite particle from a dope by jet spinning the dope to obtain a pulp, fibril or fibrid, wherein the solvent of the dope is selected from N-methyl-2-pyrrolidone, N,N′-dimethylformamide, N,N′-dimethylacetamide, tetramethylurea, and 4 to 75 wt % of a composition consisting of 2 to 95 wt % of a para-aramid polymer and 5-98 wt % of a solid additive material, to a total of 100 wt %, and wherein the aramid polymer is dissolved in the solvent; or coagulating the dope by means of a rotor-stator apparatus in which the polymer solution is applied through the stator on the rotor so that the precipitating polymer-additive composite particle is subjected to shear forces while they are in a plastic deformable stage.