Cyclone Coagulation Apparatus for Polymer Fiber Uniformity

Solution Overview

Problem

The production of polymer fibers, particularly large-tow carbon fibers, is hindered by concentration gradients around the coagulation zones during the coagulation step, leading to variability in filament formation.

Innovation Solution

A cyclone-producing apparatus is introduced, comprising a cylindrical housing with a tangentially oriented inlet, which creates cyclonic motion within the housing, ensuring uniform coagulation liquid distribution around the spinneret, thereby reducing concentration gradients.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional coagulation bath geometry is used, then the apparatus structure is simple, but concentration gradients form around the spinneret causing non-uniform solvent distribution and variability in filament formation

Engineering Contradiction:

Improveuniformity of filament formationVSAvoidcoagulation bath geometry

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The coagulation bath is segmented into distinct zones: a coagulation zone with restricted liquid access near the spinneret, and a bulk coagulation zone farther away. This segmentation prevents backflow of used coagulant to the critical coagulation zone, eliminating concentration gradients while maintaining overall system simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A baffle structure acts as an intermediary element between the spinneret and the bulk coagulation bath. The baffle restricts liquid access to the coagulation zone, preventing direct backflow of solvent-enriched coagulant while allowing the process to continue with simple bath geometry

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If laminar coagulant flow is used, then the flow pattern is stable, but the backflow rate of used coagulant varies causing non-uniform solvent concentration around the spinneret

Engineering Contradiction:

Improveuniformity of solvent concentrationVSAvoidcoagulation flow control

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The coagulation bath is segmented into distinct zones: a coagulation zone with restricted liquid access near the spinneret, and a bulk coagulation zone farther away. This segmentation prevents backflow of used coagulant to the critical coagulation zone, eliminating concentration gradients while maintaining overall system simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A baffle structure acts as an intermediary element between the spinneret and the bulk coagulation bath. The baffle restricts liquid access to the coagulation zone, preventing direct backflow of solvent-enriched coagulant while allowing the process to continue with simple bath geometry

Inventive Principle:

Principle #24Intermediary (Mediator)

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 use of the cyclone-producing apparatus results in more uniform filament diameters and circularity, reducing variability by 5 to 50% compared to processes without the apparatus, leading to higher quality polymer fibers.

Implementation Method 1

A cyclone-producing apparatus is introduced, comprising a cylindrical housing with a tangentially oriented inlet, which creates cyclonic motion within the housing

Methodology Applied

Scientific EffectCyclonic motion: Cyclone Separation

Data Source

PatentUS20250043466A1An apparatus for improved coagulation injection during the manufacture of polymer fibers, and method of use thereof

Publication Date: 2025.02.06 CYTEC IND INC

AI summary

The present disclosure relates to a cyclone-producing apparatus for use in the production of polymer fibers, such as large tow polymer fibers, typically used in the manufacture of carbon fiber. The present disclosure also relates to a system comprising the cyclone-producing apparatus and a process for producing polymer fibers using such a system. The polymer fibers produced are useful for the manufacture of carbon fiber, which finds application as structural components in composite materials relevant to many areas, such as the aerospace, marine, and automotive industries, among others.