Biodegradable Polyester Fiber Spinning via Continuous Polymerization
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Solution Overview
Problem
Existing biodegradable polymers for textiles are costly to produce using masterbatch methods and are not well-suited for continuous polymerization processes, leading to environmental persistence issues.
Innovation Solution
A continuous polymerization process incorporating caprolactone monomer, terephthalic acid, ethylene glycol, calcium carbonate, and polybutylene succinate to produce biodegradable polyester fibers, enabling high-throughput production and biodegradability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If masterbatch approach is used to produce biodegradable polymers, then biodegradability is achieved, but production cost increases and process complexity increases
Solution Approach 1:
The patent extracts the biodegradability function from the final product and embeds it into the polymerization process itself through the use of polycaprolactone pellets as a reactant. This eliminates the need for separate masterbatch compounding steps while maintaining biodegradability, thereby reducing production cost and process complexity.
Solution Approach 2:
The patent performs preliminary action by pre-preparing polycaprolactone pellets with specific molecular weight (Mw of 6400) that are designed to be directly usable in continuous polymerization. This preliminary preparation eliminates the need for subsequent compounding and drying steps, reducing both cost and process complexity while ensuring biodegradability.
2Reliability
If masterbatch approach is used to produce biodegradable polymers, then biodegradability is achieved, but production time increases and productivity decreases
Solution Approach 1:
The patent implements continuous polymerization where polycaprolactone pellets are continuously fed into the reactor and polymerized in-situ. This continuous process eliminates the batch processing steps required in masterbatch methods, significantly reducing production time and increasing productivity while maintaining biodegradability.
Solution Approach 2:
The patent removes the time-consuming masterbatch compounding, drying, and crystallization steps by directly using polycaprolactone pellets as a reactant in continuous polymerization. This extraction of unnecessary steps reduces production time and increases productivity.
3Productivity
If polycaprolactone pellets are used in continuous polymerization, then productivity increases, but the process complexity increases
Solution Approach 1:
The patent makes the polycaprolactone pellets multi-functional by designing them to serve both as the biodegradable polymer source and as the reactant for continuous polymerization. This universal approach simplifies the process by eliminating the need for separate masterbatch compounding equipment while enabling continuous production.
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 process achieves high-throughput production of biodegradable polyester fibers with desirable properties, comparable to traditional fibers, and rapid biodegradation in natural environments.
Implementation Method 1
polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, calcium carbonate, and polybutylene succinate to form a biodegradable polyester copolymer melt
Data Source
AI summary
A method is disclosed for spinning a biodegradable polyester copolymer filament. A biodegradable polyester copolymer melt is formed by polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, calcium carbonate, and poly butylene succinate to form a biodegradable polyester copolymer melt. The biodegradable polyester copolymer melt may be spun into a biodegradable polyester copolymer filament.