Polymeric Material Liquid Formulation for Stable Melt Spinning
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Solution Overview
Problem
Liquid formulations used to introduce additives into polymeric materials, such as colorants in melt-spun fibers, often lead to instability and increased filament breakages due to pressure drops at the spinneret, especially at high let-down ratios and with fine denier fibers.
Innovation Solution
A liquid formulation comprising a vehicle with specific properties, including a high flash point, weight retention, and molecular weight, combined with carbonyl bis (1-caprolactam) (CBC), which maintains stability and compatibility with polymeric materials, preventing excessive migration and fuming during fiber spinning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a liquid formulation is used to colour melt spun fibre at high let-down ratios, then the colour intensity is improved, but the melt pressure at the spinneret drops causing fibre spinning instability
Solution Approach 1:
The patent introduces a specific liquid vehicle formulation as an intermediary carrier for the colourant. This vehicle comprises a polyol ester with specific molecular weight (600-1800 g/mol) and flash point (>272°C), which mediates between the colourant and the polymer melt. The vehicle maintains colourant solubility and colour intensity while its controlled volatility and thermal properties prevent excessive pressure drops during fiber spinning, thus resolving the contradiction between colour intensity and spinning stability
Solution Approach 2:
The patent changes the physical and chemical parameters of the liquid formulation, specifically selecting a polyol ester with controlled molecular weight (600-1800 g/mol) and flash point (>272°C). These parameter changes optimize the balance between colourant dissolution capability (for intensity) and thermal stability/volatility control (for pressure stability during spinning). The specific molecular weight range ensures adequate solubility without excessive viscosity, while the flash point ensures thermal stability at processing temperatures
2Illumination intensity
If the let-down ratio is increased to achieve dark shades, then the colour depth is improved, but the melt pressure drop increases leading to increased filament breakages
Solution Approach 1:
The liquid vehicle acts as a protective intermediary that enables high let-down ratios for dark shades while protecting the polymer melt from excessive pressure drops. The vehicle's specific molecular weight and flash point properties allow it to maintain colourant solubility at high concentrations (for depth) while its controlled volatility profile prevents the severe pressure drops that cause filament breakages
Solution Approach 2:
By changing the liquid vehicle parameters to a polyol ester with molecular weight 600-1800 g/mol and flash point >272°C, the formulation achieves adequate colour depth at high let-down ratios while the controlled volatility and thermal properties maintain sufficient melt pressure to prevent filament breakages during spinning
Data Source
AI summary
A liquid formulation for addition to a polymeric material comprises a vehicle, an additive (e.g. a colourant) and carbonyl bis (1-caprolactan)). The liquid formulation may be used to colour melt spun fibre (e.g. PET or polyamide).