System and method of dosing a polymer mixture with a first solvent, device, system and method of extracting solvent from at least one polymeric yarn, system and method of mechanical pre-recovery of at least one liquid in at least one polymeric yarn, and continuous system and method for producing at least one polymeric yarn
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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 deformation control, which affect the mechanical properties of the yarns.
Innovation Solution
A continuous mineral oil-based method and system for producing UHMWPE yarns that reduces the amount of second solvent used, optimizes yarn residence time, and employs a suspension dosing device to deliver a homogeneous polymer mixture, incorporating a pre-recovery system for efficient solvent extraction and a drying process to maintain microstructure integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If decalin-based or mineral oil-based gel spinning processes are used to produce UHMWPE yarns, then high mechanical strength and elastic modulus are achieved, but industrial safety concerns arise due to flammable solvents and high capital and operational expenditures occur
Solution Approach 1:
The patent changes the chemical composition parameters of the solvent system by using a mixture of decalin and mineral oil in specific ratios (e.g., 30-70 wt% decalin and 70-30 wt% mineral oil). This parameter modification maintains the solubility and spinning performance needed for high-strength yarns while reducing the overall flammability and environmental harm compared to pure decalin systems
Solution Approach 2:
The invention creates a composite solvent system combining two different solvents (docalin and mineral oil) with complementary properties. Decalin provides good solubility and spinning characteristics, while mineral oil reduces flammability and environmental impact. The composite solvent system achieves both high mechanical performance and improved safety profile
2Strength
If solvents are used in gel spinning processes, then polymer chain orientation and high mechanical performance are achieved, but environmental impact increases and solvent recovery becomes difficult
Solution Approach 1:
The patent modifies the solvent composition parameters by incorporating mineral oil (a less environmentally harmful substance) into the decalin-based system. This parameter change reduces the environmental impact while maintaining the functional performance needed for high-strength yarn production
Solution Approach 2:
The invention implements a solvent recovery system that collects and recycles both decalin and mineral oil from the spinning process. The recovered solvents are purified and reused, reducing environmental discharge and operational costs. The system efficiently separates and recovers the solvent mixture from the yarn product
3Loss of substance
If traditional extraction methods are used for solvent removal, then solvent recovery is achieved, but yarn deformation occurs and mechanical properties deteriorate
Solution Approach 1:
The patent applies preliminary mechanical actions (such as controlled drawing and tensioning) to the yarn before the extraction process. This preliminary treatment stabilizes the yarn structure and reduces subsequent deformation during solvent removal. The yarn is pre-oriented and pre-conditioned to withstand the extraction process with minimal dimensional changes
Solution Approach 2:
The invention employs dynamic extraction conditions where extraction parameters (such as solvent flow rate, temperature, and exposure time) are continuously adjusted based on yarn response. This dynamic control prevents excessive deformation while ensuring complete solvent removal. The extraction process adapts in real-time to maintain yarn integrity
4Productivity
If continuous production methods are implemented, then productivity increases, but process complexity and control difficulty increase
Solution Approach 1:
The patent divides the continuous production process into distinct functional segments (mixing, spinning, extraction, drying, winding) that can be independently optimized and controlled. Each segment handles a specific task, allowing for simplified control of individual processes while achieving high overall productivity through continuous operation across all segments
Solution Approach 2:
The invention designs multi-functional equipment that performs multiple operations within single units. For example, the spinning apparatus simultaneously accomplishes solution delivery, yarn formation, and initial orientation. The extraction system handles both solvent removal and yarn conditioning. This multi-functionality reduces the number of separate devices needed while maintaining continuous high-speed production
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 improved mechanical properties and reduced environmental impact by efficiently recovering solvents, minimizing deformation, and lowering operational costs, resulting in high-quality UHMWPE yarns with enhanced tenacity and modulus.
Implementation Method 1
mixing a polymer with a first solvent to form a mixture
Implementation Method 2
extracting solvent from at least one polymeric yarn
Implementation Method 3
drying process to maintain microstructure integrity
Data Source
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.