Method for producing treatment agent for synthetic fibers, treatment agent for synthetic fibers, synthetic fibers, and method for producing synthetic fibers
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Solution Overview
Problem
Fluffing occurs during the spinning step of synthetic fiber production, which existing methods fail to adequately suppress, affecting the quality and smoothness of the fibers.
Innovation Solution
A synthetic fiber treatment agent is developed, comprising a (poly)oxyalkylene derivative and a smoothing agent, with a boron content of no more than 200 ppm, prepared by adding alkylene oxide to an alcohol under the presence of a catalyst and subsequent removal of the catalyst to minimize boron content, ensuring effective suppression of fluffing during the spinning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional treatment agent containing amino-modified silicone and polyoxyalkylene alkyl ether is used, then the fiber treatment is applied, but fluffing occurs during the spinning step and cannot be suppressed
Solution Approach 1:
The invention changes the chemical composition parameters of the treatment agent by specifying a (poly)oxyalkylene derivative with controlled alkylene oxide addition ratio (1-30 moles per mole of alcohol) and strict boron content limits (≤200 ppm, preferably ≤40 ppm). These parameter changes in composition enable effective fluffing suppression while maintaining treatment performance
Solution Approach 2:
The invention extracts and removes the harmful catalyst (boron-containing substance) from the treatment agent system through a removal step that reduces boron content to ≤200 ppm. This extraction of the harmful catalytic component eliminates the fluffing problem while preserving the beneficial treatment properties
2Object-affected harmful factors
If the boron content in the treatment agent is reduced to suppress fluffing, then fluffing is suppressed, but the catalyst must be removed which adds process complexity
Solution Approach 1:
The invention uses an intermediary substance (ion exchange resin or adsorbent) to remove the boron-containing catalyst from the treatment agent. This intermediary mediates between the need to eliminate fluffing (by removing catalyst) and the desire to maintain simple processing, providing an effective yet manageable removal approach
3Manufacturing precision
If the (poly)oxyalkylene derivative is used with controlled boron content, then fluffing is suppressed and smoothness is improved, but the addition step and removal step increase manufacturing complexity
Solution Approach 1:
The invention performs preliminary action by controlling the catalyst content during the addition step and planning for its subsequent removal. The (poly)oxyalkylene derivative is prepared with controlled boron content from the beginning, and the removal step is built into the process design, allowing smoothness improvement while managing manufacturing complexity through advance planning
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 treatment agent successfully suppresses fluffing in the spinning step, improves the smoothness and bundling properties of the fibers, and enhances wetting properties, leading to better adhesion and uniform application on synthetic fibers.
Implementation Method 1
an addition step of adding an alkylene oxide to an alcohol under presence of a catalyst having a boron atom in its molecule to prepare a (poly)oxyalkylene derivative
Implementation Method 2
a synthetic fiber to which the synthetic fiber treatment agent is adhered
Data Source
AI summary
The present invention addresses the problem of suitably suppressing fluffing during a spinning process. This method for producing a treatment agent for synthetic fibers, wherein the boron content in the nonvolatile content of the treatment agent for synthetic fibers as detected by ICP emission spectrometry is 200 ppm or less, comprises: an addition step wherein a (poly)oxyalkylene derivative is produced by adding an alkylene oxide to an alcohol in the presence of a catalyst that has a boron atom in each molecule; and a removal step wherein the catalyst is removed so that the boron content in the nonvolatile content of the treatment agent for synthetic fibers as detected by ICP emission spectrometry becomes 200 ppm or less.