System and method of mechanical pre-recovery of at least one liquid in 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 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 extracts and removes the harmful flammable solvent (decalin or mineral oil) from the spinning process by using water as a替代 medium. The gel yarn is produced in an aqueous environment, eliminating the need for hazardous organic solvents while maintaining the gel spinning mechanism that produces high-strength UHMWPE yarns.
Solution Approach 2:
The patent changes the fundamental parameter of the spinning medium from organic solvent to water-based aqueous suspension. This parameter change transforms the process from using flammable decalin or mineral oil to using non-flammable water, thereby eliminating industrial safety concerns while preserving the ability to produce high-performance yarns.
2Loss of substance
If traditional solvent extraction methods are used to recover solvents from gel yarn, then solvent recovery is achieved, but deformation control difficulties affect the mechanical properties of the yarns
Solution Approach 1:
The patent takes out the problematic solvent extraction step entirely by using water as the spinning medium. Since water is already present in the gel yarn structure and is non-hazardous, the process eliminates the need for complex extraction operations using secondary solvents, thereby avoiding deformation issues while achieving complete solvent recovery through simple evaporation or filtration.
Solution Approach 2:
The aqueous-based process is self-service in that water naturally evaporates or can be easily removed without requiring additional extraction solvents or complex equipment. The gel yarn structure itself maintains the water within the polymer matrix, and removal occurs through simple drying processes that do not cause deformation, making the system self-sufficient and avoiding external intervention that could damage the yarn.
3Productivity
If continuous production methods are used to increase productivity, then output is improved, but homogeneous mixture delivery and microstructure integrity become more difficult to maintain
Solution Approach 1:
The patent applies preliminary action by pre-mixing the UHMWPE powder with water and dispersing agents in a homogeneous suspension before the spinning process. This pre-prepared aqueous suspension ensures uniform distribution of polymer particles throughout the water medium, which maintains mixture homogeneity during continuous production and prevents variations in yarn microstructure even at high output rates.
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 minimizing solvent usage and enhancing solvent recovery efficiency, while maintaining the high performance characteristics of UHMWPE yarns.
Implementation Method 1
employs a suspension dosing device to deliver a homogeneous polymer mixture
Implementation Method 2
incorporating a pre-recovery system for efficient solvent extraction
Implementation Method 3
and a drying process to maintain microstructure integrity
Data Source
Figure 1
Figure 2
Figure 3a~3
AI summary
The present invention is directed to a method and system of pre-recovery of at least one liquid in at least one polymeric yarn. with mechanical retention of the liquid of the polymeric yarn surface.