Condensation Polyurethane Fiber for Smooth Melt Spinning
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Solution Overview
Problem
Existing condensation type non-isocyanate polyurethane (NIPU) processes face issues with insufficient molecular entanglement and cohesion, leading to poor yarn uniformity and breakage during spinning, and the die swell ratio is not effectively controlled, affecting the physical properties of the fiber.
Innovation Solution
A condensation type polyurethane fiber with a specific structure and terminal groups, characterized by an amine value of not less than 10 meq/kg and a coefficient of variation (CV) not greater than 6, is developed, allowing for melt spinning without a chain extender, and incorporating a carbamation reaction using diamine, carbonate, and diol compounds to form a condensation type polyurethane resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If condensation type NIPU is used for melt spinning, then the process is green and environmentally friendly, but the linear molecular structure causes insufficient molecular entanglement and poor cohesion
Solution Approach 1:
The patent changes the molecular structure parameters by introducing terminal groups with specific chemical compositions (formula 2) that enable hydrogen bonding. This structural modification allows the condensation type NIPU to achieve sufficient molecular cohesion and entanglement for melt spinning while maintaining the environmental benefits of the green process.
2Ease of operation
If chain extender is added to increase molecular weight, then spinning smoothness improves, but die swell ratio cannot be effectively controlled and broken yarns still occur
Solution Approach 1:
Instead of simply increasing molecular weight through chain extenders, the patent changes the chemical structure by incorporating terminal groups (formula 2) that provide hydrogen bonding capability. This structural parameter change achieves both spinning smoothness and die swell control by enhancing molecular cohesion without excessive molecular weight increase.
Solution Approach 2:
The patent creates a composite molecular structure combining the condensation type NIPU backbone with terminal groups containing hydrocarbon or carbon-hydrogen-oxygen groups. This composite structure provides both the processability needed for smooth spinning and the cohesion required for controlled die swell and reduced breakage.
3Manufacturing precision
If organic solvents are used for recrystallization purification of diaminoester diol monomer, then purification is achieved, but large amount of waste liquid is generated and process becomes energy-consuming
Solution Approach 1:
The patent extracts and eliminates the need for organic solvent recrystallization purification step by directly using the diaminoester diol monomer in the polymerization reaction. This removes the source of waste liquid generation and energy consumption while maintaining the quality of the final product.
Solution Approach 2:
The patent employs a self-service approach where the diaminoester diol monomer is directly utilized without requiring external purification processes. The monomer's inherent properties allow it to function effectively in the condensation reaction with polyol, eliminating the need for solvent-based purification and reducing environmental impact.
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 smooth melt spinning and achieves good fiber uniformity with controlled die swell ratio, resulting in a condensation type polyurethane fiber with improved physical properties and reduced breakage.
Implementation Method 1
incorporating a carbamation reaction using diamine, carbonate, and diol compounds to form a condensation type polyurethane resin
Implementation Method 2
the terminal groups having a structure as shown in formula (2): in which R1 and R3 independently include a first organyl group of C2-C20, and the first organyl group includes a hydrocarbon group or a group having carbon, hydrogen, and oxygen
Data Source
AI summary
The present invention provides a condensation type polyurethane fiber. The condensation type polyurethane fiber includes a condensation type polyurethane, the condensation type polyurethane includes a plurality of first segments having a plurality of terminal group having which is bonded to R2 of at least one of the first segments. R1 and R3 independently include a first organyl group of C2-C20. The first segments have the same or different R2. R2 includes a second organyl group of C2-C20. The amine value of the condensation type polyurethane is at least 10 meq/kg. The coefficient of variation of the condensation type polyurethane fibers is less than 6.