Polymeric Yarn Solvent Extraction Using Volatile Solvent Substitution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing ultra-high molecular weight polyethylene (UHMWPE) yarns, such as the decalin-based and mineral oil-based gel spinning processes, face challenges including industrial safety concerns due to flammable solvents, high capital and operational expenditures, environmental impact, and difficulties in solvent recovery and mechanical property maintenance.
Innovation Solution
A continuous mineral oil-based method and system for producing UHMWPE yarns with optimized solvent extraction, utilizing a suspension dosing system to deliver a homogeneous polymer-solvent mixture, followed by precise control of yarn residence time and solvent substitution with a more volatile solvent for efficient solvent recovery, reducing the amount of second solvent required and enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mineral oil-based gel spinning process is used, then mechanical properties of UHMWPE yarns are maintained, but industrial safety concerns arise due to flammable solvents and environmental impact increases
Solution Approach 1:
The patent changes the physical-chemical parameters of the solvent system by using a mixture of mineral oil and aromatic hydrocarbon instead of pure mineral oil. This parameter change reduces the flash point and flammability of the solvent system while maintaining its solvent capabilities, thereby improving industrial safety and environmental compatibility without sacrificing the mechanical properties of the UHMWPE yarns
Solution Approach 2:
The patent employs a composite solvent system combining mineral oil and aromatic hydrocarbon in specific proportions. This composite approach leverages the complementary properties of both solvents: mineral oil provides good solvent power for UHMWPE while aromatic hydrocarbon reduces flammability and improves safety, achieving a balance between mechanical property maintenance and harm reduction
2Productivity
If decalin-based gel spinning process is used, then production efficiency is improved, but capital and operational expenditures increase and solvent recovery becomes difficult
Solution Approach 1:
The patent modifies the solvent composition parameters to use a mineral oil and aromatic hydrocarbon mixture that enables easier solvent recovery through conventional separation techniques. The specific composition ratios are optimized to maintain production efficiency while improving the feasibility and economics of solvent recovery operations
Solution Approach 2:
The aromatic hydrocarbon component acts as an intermediary substance that facilitates the separation and recovery of the mineral oil solvent. The mixture composition is designed so that the aromatic hydrocarbon can be easily separated from the UHMWPE yarn, allowing for efficient recovery and reuse of the mineral oil, thereby reducing operational expenditures
3Object-affected harmful factors
If solvent extraction is performed to recover solvents, then environmental impact is reduced, but mechanical properties of yarns may deteriorate and process complexity increases
Solution Approach 1:
The patent optimizes the extraction process parameters including temperature, time, and solvent mixture composition to achieve effective solvent removal while preserving the mechanical integrity of the UHMWPE yarns. The specific parameter ranges are controlled to prevent yarn degradation during extraction
Solution Approach 2:
The patent implements a continuous extraction process where solvents are progressively removed through controlled stages. This continuous action allows for gradual solvent elimination without subjecting the yarn to harsh conditions that could damage its mechanical properties, while still achieving the environmental benefits of solvent recovery
4Loss of substance
If more second solvent is used for extraction, then solvent recovery efficiency is improved, but process complexity and operational expenditures increase
Solution Approach 1:
The patent optimizes the ratio and composition of the second solvent to achieve high solvent recovery efficiency with minimal process complexity. The specific composition parameters are tuned to maximize extraction effectiveness while avoiding the need for complex multi-stage extraction systems or additional processing equipment
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 method achieves efficient solvent recovery, reduces industrial hazards, and maintains high mechanical properties of the UHMWPE yarns, making the process more economically viable and environmentally friendly compared to existing technologies.
Implementation Method 1
dissolving the polymer mixture in a first solvent to form a solution
Implementation Method 2
dipping the solution into a quenching bath to coagulate and form gel yarn
Implementation Method 3
drawing the gel yarn through a liquid medium to substitute the first solvent with a second more volatile solvent
Implementation Method 4
the second solvent is evaporated to dry the gel yarn
Data Source
Figure 1
Figure 2
Figure 3~3a
AI summary
The present invention is directed to a method and a system for the production of at least one polymeric yarn comprising means for mixing a polymer (1) with a first solvent yielding a mixture; means for homogenizing the mixture; means for rendering the mixture inert (21, 22, 23); means for dipping the mixture into a quenching bath (30), wherein an air gap is maintained before the mixture reaches the quenching bath (30) liquid surface forming at least one polymeric yarn; means for drawing (41) the at least one polymeric yarn at least once; means for washing (5) the at least one polymeric yarn with a second solvent that is more volatile than the first solvent; means for heating the at least one polymeric yarn (6); means for drawing at room temperature (7) the at least one polymeric yarn at least once; and means for heat drawing (8) the at least one polymeric yarn at least once. The instant invention also concerns a system and method of dosing a polymer mixture with a first solvent into an extruder (26), a device (5), a system and a method of solvent extraction from at least one polymeric yarn, and a method and system of mechanical pre-recovery (4) of at least one liquid in at least one polymeric yarn.