Polyester binder fiber with amorphous polyether imide for thin high-strength paper

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Solution Overview

Problem

Conventional polyester binder fibers face issues with fiber breakage and water dispersibility at low fineness, and high crystallization temperature leads to thicker papers with reduced melting difficulty, making it challenging to achieve high-strength, thin paper structures.

Innovation Solution

Incorporating an amorphous polyether imide in a proportion of 0.1 to 5.0 mass% into the polyester resin to lower crystallization temperature and enhance adhesiveness, resulting in a polyester binder fiber with a single fiber fineness of 0.01 to 10 dtex and a crystallization temperature between 100°C and 250°C, which improves processability and bonding strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the single fiber fineness of polyester binder fiber is reduced to below 1.0 dtex to achieve thinner paper, then paper thickness is reduced, but fiber breakage increases and water dispersibility deteriorates

Engineering Contradiction:

Improvepaper thicknessVSAvoidfiber breakage and water dispersibility

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The invention changes the chemical composition parameter of the polyester resin by incorporating a specific copolymer component (tetrabromoquinone and formaldehyde condensation product) in controlled amounts (0.1-5 mass%). This compositional parameter change enables the production of ultra-fine fibers (0.01-10 dtex) with improved tenacity and water dispersibility, resolving the contradiction between fiber fineness and fiber performance.

Inventive Principle:

Principle #35Parameter changes

2Strength

If binder fiber with high crystallization temperature is used to achieve high paper strength, then paper strength is improved, but paper thickness increases due to difficulty in melting

Engineering Contradiction:

Improvepaper strengthVSAvoidpaper thickness

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The invention modifies the crystallization temperature parameter of the binder fiber by incorporating the copolymer component, which lowers the crystallization temperature to enable easier melting and bonding at lower temperatures. This allows production of high-strength paper with reduced thickness, as the binder fiber can effectively bond at lower temperatures without requiring excessive thickness for strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite polyester resin system combining the base polyester with the copolymer component (tetrabromoquinone and formaldehyde condensation product). This composite material structure provides both the strength needed for high paper strength and the lowered crystallization temperature for thin paper production, resolving the contradiction between strength and thickness.

Inventive Principle:

Principle #40Composite materials

3Strength

If conventional polyester binder fiber is used to achieve high paper strength, then paper strength is improved, but processability deteriorates due to high crystallization temperature

Engineering Contradiction:

Improvepaper strengthVSAvoidprocessability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention changes the thermal parameter (crystallization temperature) of the polyester binder fiber through copolymer incorporation, lowering it from conventional high temperatures to a range that improves processability. This parameter change enables easier melting and bonding during paper production while maintaining high paper strength, thus resolving the contradiction between strength and ease of manufacture.

Inventive Principle:

Principle #35Parameter changes

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 solution enables the production of high-strength, thin paper structures with improved adhesiveness and reduced thickness, allowing for higher pressure applications and cost reduction by bonding drawn polyester fibers effectively, while maintaining efficient processing.

Implementation Method 1

a crystallization temperature measured by differential calorimetry in a range of 100°C or higher and 250°C or lower

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentEP3561161B1Polyester binder fiber

Publication Date: 2022.03.16 KURARAY CO LTD

AI summary

The problem to be solved by the present invention is to provide a polyester binder fiber having a low crystallization temperature and exhibiting improved adhesiveness and a fiber structure including the polyester binder fiber. The polyester binder fiber according to the present invention includes a polyester polymer and an amorphous polyether imide polymer in a proportion of 0.1 to 5.0 mass% (based on the mass of the polyester polymer), and the polyester binder fiber has a crystallization temperature measured by differential calorimetry in a range of 100°C or higher and 250°C or lower.