Multicomponent Fiber with PPS Core and Thermoplastic Sheath

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Solution Overview

Problem

The production of polyphenylene sulfide (PPS) fibers is hindered by their affinity for metal surfaces, leading to poor spinning characteristics and frequent contamination of spinneret nozzles, disrupting the continuous spinning process.

Innovation Solution

A multicomponent fiber is developed with a polyarylene sulfide core and a thermoplastic polymer sheath, such as polyethylene terephthalate, that completely surrounds the PPS core, minimizing nozzle plugging and allowing for continuous spinning while maintaining chemical and flame-resistant properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If PPS polymer is used for fiber production, then thermal and chemical resistance is improved, but spinneret nozzle contamination occurs due to affinity for metal surfaces

Engineering Contradiction:

Improvethermal and chemical resistanceVSAvoidspinneret nozzle contamination

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

A metal coating is applied to the spinneret nozzle to serve as an intermediary layer between the PPS polymer and the metal surface. This coating prevents direct affinity interaction between PPS and metal, eliminating nozzle contamination while allowing continuous fiber production to proceed

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The metal coating on the spinneret nozzle is designed as a sacrificial, replaceable layer that protects the main nozzle structure. When the coating becomes contaminated, it can be removed and reapplied or the nozzle replaced, avoiding the need to discard the entire spinneret assembly

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Productivity

If PPS polymer is spun continuously, then productivity is improved, but frequent shutdowns are required to address nozzle contamination

Engineering Contradiction:

Improvecontinuous spinning outputVSAvoidspinning process continuity

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The metal coating acts as a mediator that prevents PPS polymer from adhering to the spinneret nozzle, enabling truly continuous spinning operations without periodic shutdowns for cleaning or nozzle replacement

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

By preventing nozzle contamination through the metal coating, the spinning process can maintain continuous operation without interruption, maximizing productivity and eliminating downtime associated with addressing nozzle blockages

Inventive Principle:

Principle #20Continuity of useful action

3Strength

If PPS affinity for metal surfaces is utilized, then material bonding is improved, but fiber production is disrupted due to nozzle sticking

Engineering Contradiction:

Improvematerial bondingVSAvoidspinning process operation

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The metal coating provides a controlled surface that manages PPS affinity, allowing proper material bonding within the fiber structure while preventing unwanted adhesion at the nozzle interface that would disrupt operation

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP2220272B1Multicomponent fiber with polyarylene sulfide component

Publication Date: 2019.05.08 EI DU PONT DE NEMOURS & CO

Figure 1~3

AI summary

This invention relates to a multicomponent fiber having an exposed outer surface, comprising at least a first component of polyarylene sulfide polymer, and at least a second component of a thermoplastic polymer free of polyarylene sulfide polymer, wherein said thermoplastic polymer forms the entire exposed surface of the multicomponent fiber.