Polymeric Material Additive Incorporation via Ester Vehicle
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Solution Overview
Problem
Current methods for incorporating additives into polymeric materials, such as polyester fibers, face challenges including time-consuming processes, cleaning issues with extruders, and detrimental effects on material properties, particularly when using masterbatches or liquid formulations that can lead to carrier degradation and poor properties.
Innovation Solution
A method involving a liquid formulation with an additive and a vehicle comprising aliphatic or aromatic tri- or di-carboxylic acid esters, which is contacted with the polymeric material during melt processing, allowing for efficient and stable introduction of additives without significant detrimental effects on the material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid formulation with carrier medium is used to introduce additive into polymer melt, then additive incorporation is achieved, but carrier degradation and die head pressure drop occur
Solution Approach 1:
The invention extracts and eliminates the harmful carrier medium from the formulation, using only the aliphatic or aromatic tri- or di-carboxylic acid ester vehicle which does not cause degradation or pressure drop issues. The additive is incorporated directly using this simplified vehicle system.
Solution Approach 2:
The aliphatic or aromatic tri- or di-carboxylic acid ester acts as an intermediary vehicle that enables additive incorporation without the harmful effects of traditional carriers. It mediates between the additive and polymer melt, providing solubility and compatibility without degradation.
2Reliability
If masterbatch pellets are used to introduce additives into polymer, then additive incorporation is achieved, but extruder cleaning becomes time-consuming
Solution Approach 1:
The invention extracts the masterbatch pellet form and replaces it with a liquid formulation that can be easily introduced into the polymer melt. This eliminates the need for extensive extruder cleaning between color changes, reducing downtime significantly.
Solution Approach 2:
The invention changes the physical state parameter of the additive formulation from solid masterbatch pellets to liquid formulation. This parameter change enables easier incorporation into the melt and simplifies extruder cleaning requirements.
3Ease of operation
If liquid formulation with conventional carrier is used, then additive can be introduced into polymer melt, but poor properties of polymeric material result
Solution Approach 1:
The aliphatic or aromatic tri- or di-carboxylic acid ester serves as a superior intermediary vehicle that maintains polymer material properties while enabling additive introduction. It provides the necessary solubility and compatibility without the detrimental effects of conventional carriers.
Solution Approach 2:
The invention changes the chemical composition parameter of the vehicle from conventional carrier mediums to specific aliphatic or aromatic tri- or di-carboxylic acid esters. This parameter change preserves the polymeric material properties while achieving effective additive incorporation.
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
This method enables the effective introduction of additives into polymeric materials prior to or during melt-processing, maintaining the properties of the materials and improving processing efficiency, with the vehicle being pumpable, stable, and compatible with the polymer, reducing haze and clouding in moldings.
Implementation Method 1
a liquid formulation comprising an additive (for example a colourant) and a vehicle comprising an aliphatic or aromatic tri- or di-carboxylic acid
Implementation Method 2
contacting the liquid formulation with said polymeric material in a melt processing apparatus
Data Source
AI summary
A method of introducing an additive into a polymeric material comprises using a liquid formulation comprising an additive, for example a colorant, and a vehicle comprising an aliphatic or aromatic tri- or di-carboxylic acid covalently linked by ester bonds to two or more chains. The method involves contacting the liquid formulation with the polymeric material in a melt processing apparatus. The cavity transfer mixer may be used in the process. A fiber is suitably subsequently produced.