PEF Melt-Spun Fiber Drawing for Fine Denier and High Tenacity
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Solution Overview
Problem
Existing polyethylene-2,5-furan-dicarboxylate fibers suffer from unintended coloration and low thermal stability, along with limited molecular weight and tenacity, making them unsuitable for high-performance applications.
Innovation Solution
A process for preparing polyethylene-2,5-furan-dicarboxylate fibers through melt spinning, involving a molten composition with high intrinsic viscosity, which is drawn to a low linear density, resulting in fibers with enhanced tenacity and crystallization, and potentially blended with other polymers like PET or PEN to improve properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts (Co, Mn, Ce) are used for polyester preparation, then polymerization reaction efficiency is improved, but the polyester becomes unintentionally colored and thermally unstable
Solution Approach 1:
The patent changes the chemical parameter of the catalyst system by using organic metal compounds (aluminum, zinc, magnesium, beryllium, or silicon-based catalysts) instead of conventional Co, Mn, or Ce catalysts. This parameter change resolves the contradiction by maintaining high polymerization efficiency while eliminating the harmful coloration and thermal instability effects caused by conventional catalysts.
Solution Approach 2:
The patent employs catalysts that do not persist as harmful residues in the final polyester product. The organic metal catalysts are designed to be effective during the polymerization process but do not cause long-term degradation or coloration, effectively serving their purpose and then being eliminated or deactivated without harmful effects.
2Quantity of substance
If solid state polymerization is used to achieve high molecular weight, then molecular weight is improved, but the process complexity and time consumption increase
Solution Approach 1:
The patent performs preliminary action by conducting melt polymerization under optimized conditions that directly produce high molecular weight polyester without requiring subsequent solid state polymerization. The catalyst system and polymerization conditions are pre-optimized to achieve high molecular weight in a single step, eliminating the need for additional solid state polymerization equipment and process steps.
3Length of moving object
If fiber drawing is performed to achieve low linear density, then fiber fineness is improved, but tenacity may be reduced without proper molecular weight
Solution Approach 1:
The patent changes the molecular weight parameter of the polyester to a sufficiently high level (intrinsic viscosity ≥ 0.55 dl/g) before fiber drawing. This parameter change ensures that the polymer chains have adequate length and entanglement to maintain tenacity during the drawing process that reduces linear density, resolving the contradiction between fiber fineness and strength.
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 yields fibers with excellent mechanical properties, high tenacity, and desirable linear density, suitable for textile applications, while maintaining a colorless and high molecular weight profile, and allows for the retention or improvement of properties from blended polymers.
Implementation Method 1
a molten composition comprising polyethylene-2,5-furan-dicarboxylate having an intrinsic viscosity of at least 0.55 dl/g, determined in dichloroacetic acid at 25°C, is passed through one or more spinning openings to yield molten threads
Implementation Method 2
the molten threads are cooled to below the melting temperature of the composition to yield spun fibers
Implementation Method 3
the molten threads are cooled to below the melting temperature of the composition to yield spun fibers
Implementation Method 4
the spun fibers are drawn to a linear density in the range of 0.05 to 2.0 tex per fiber
Data Source
AI summary
A fiber comprising polyethylene-2,5-furan-dicarboxylate, is prepared by melt spinning in a process wherein a molten composition comprising polyethylene-2,5-furan-dicarboxylate having an intrinsic viscosity of at least0.55 dl/g, determined in dichloroacetic acid at 25°C, is passed through one or more spinning openings to yield molten threads; wherein the molten threads are cooled to below the melting temperature of the composition to yield spun fibers; and wherein the spun fibers are drawn to a linear density in the range of 0.05 to 2.0 tex per fiber. The invention also proves a fiber comprising polyethylene-2,5-furan-dicarboxylate having a linear density of 0.05 to 2.0 tex, wherein the polyethylene-2,5-furan-dicarboxylate has an intrinsic viscosity of at least0.45 dl/g, determined in dichloroacetic acid at 25°C.