Patent Application
20180250867
The invention relates to a method and a device for admixing additives into a polymer melt, which is combined in a highly concentrated form with a further melt flow without additives and mixed therewith. This melt, back-mixed to a required final concentration, is ultimately fed to various end uses.
The background of the invention is the lack of flexibility of large-scale polymer plants, for example those encountered in the polyamide 6 (PA 6) field. For certain end uses, polymers are specifically provided with functional and/or color additives to impart a desired color to the polymer, to influence its mechanical, optical, or haptic properties, to provide flame retardant or antistatic properties, and the like. For example, the polymers are mixed with a TiO2 pigment or blackened with carbon black. If these additives are already added during the polymer production process, as is customary, the entire melt-carrying part of the production plant is naturally contaminated with the respective additive. Switching to other additives or to a product with different additives requires an extensive and lengthy cleaning process of the entire production plant, rendering such systems, which usually have very high throughput capacity, very inflexible.
Therefore, processes are desirable which allow an additive to be added only after the polymerization has been completed and thus ensure flexibility for different end products with different additives while at the same time enabling rapid product changes.
The polyamide 6 produced via the polymerization process contains, directly after completion of the polymerization, still a proportion of about 10% by weight of low molecular weight substances, so-called extracts. These must be largely removed i.e., extracted, in order to obtain a processable product for further processing. The non-extracted PA 6 leaving the polymerization process is thus an intermediate in the value-creation chain.
There are various prior art systems for rendering large-scale plants more flexible. DE 1 604 368 A1 describes the addition of masterbatch in a melt flow. However, a disadvantage of this method is that the material is subjected to handling to some degree and thus always involves the risk of contamination and re-melting leads to a reduction in quality as a result of polymeric degradation. Moreover, there are additional costs for drying the granules and higher costs for the separate production of the masterbatch.
In a further process (Chemical Eng., Progress 78 (1982) 1, 62 et seq.), the polymer granulate as well as additives, such as TiO2, are added together to the first extruder zone. In this case, there is always the problem of a possible compacting of the additives between the granules. It is usually very difficult to dissolve this compaction in the dispersing process and, due to the required high shear rates, usually leads to an undesirable reduction in molecular weight of the matrix polymer. In addition, this procedure usually uses a premix of the various substances. In a premix, however, there is always the risk of segregation of the individual substances contained in the premix.
In another method, melt from the polymerization process is fed into a melt line, from which a side-flow is branched off to a dispersing extruder. The melt flow is recycled after incorporation of the additives back into the main flow of melt where they are mixed (Chemiefaser/Textgilindustrie 1 (1986) 24 et seq.). Temporally and locally after feeding the melt into the extruder, additives, including TiO2, are added directly from above into the melt. The thermals or the rising outgassing products from the melt hereby have a negative effect. Admixed additive has a gluing effect and the flowability deteriorates. This leads to inhomogeneities in the local and temporal additive distribution in the end product and additive agglomerates are generated, which then clog the melt filter and also cause an increased thread break rate in a subsequent spinning process.
DE 40 39 857 A1 describes a further development of the method described in “Chemiefaser/Textilindustrie 1 (1986) 24 et seq.” To avoid thermal bonding of the additives in the feed area and thus inhomogeneities in the final product, the additives, such as TiO2, are dosed from above a downpipe into the first extruder housing. Downstream, polymer melt, preferably consisting of polyethylene terephthalate (PET) or PA 6, is added via a melt pump. The polymer melt is previously diverted from a main melt line. The additives are dispersed in a twin-screw extruder, the melt treated with additive is returned to the main melt line, mixed with the main melt flow in the main melt line and diluted to the desired final concentration. The screw elements in the additive-dosing area were abraded to prevent compaction effects.
The aim of the invention disclosed in DE 40 39 857 A1 was to realize an agglomerate-free modification of the melt and thus extended filter life. According to the description in DE 40 39 857 A1, significantly lower screw speeds are required according to the invention than in the prior art. Thus, owing to the lower shear, only a minimal and constant reduction of the viscosity of the polymer melt is obtained and, moreover, the thermal problem does not arise, which is intended to prevent limitation of the amount of added additive. The same reasoning can be found in WO 2012/168252 A1. The advantage of the inventions according to DE 40 39 857 A1 and WO 2012/168252 A1 is thus that for example TiO2 can disperse without having to resort to high rotational speeds.
According to the description high speeds lead to polymer degradation or to reduced viscosity until the polymer becomes entirely useless. Thus, screw speeds for polyester of 250 min−1 and for PA 6 of even only 150 min−1 are used. Higher speeds were not considered for maintaining viscosity. As a result of the used low rotational speeds required for the described process, the machine throughput is consequently low or lower than would be possible if the rotational speeds could be increased without loss of quality. It would therefore be desirable to have the highest possible rotational speeds while maintaining or, ideally, improving the product properties. In addition, DE 40 39 857 A1 gives no indication of end product qualities such as a Full Dull additive, which for example correspond to a TiO2 end product concentration of 1.7 to 1.8 wt. % in the case of PA 6.
For PET in Example 3, TiO2 side-flow concentrations of at most 16% by weight are described, but this melt is diluted to a Semi-Dull final concentration of 0.4% by weight. Information about the much more demanding Full Dull end product is completely missing. However, the re-dilution is known to be an extremely critical point of the process. Particulate additives such as TiO2 are usually dispersed in the dispersing unit to a defined degree of homogenization or to a defined particle size. However, as soon as they leave the dispersing zone of the compounder, additives such as TiO2 tend to form larger, cohesive particle accumulations due to their polarity, i.e., re-agglomeration occurs.
Re-agglomeration is the greater the higher the additive concentration in the melt and usually presents a major problem. Experience has shown that side-flow concentrations of 15 wt. % and more in with respect to a Full Dull end product form such large re-agglomerates that melt filters must be replaced early and/or problems in further processing arise. For example, if not filtered out, re-agglomerates lead to increased thread breakage in the spinning mill. However, if the re-agglomerates occur in large numbers and are filtered out, the result is a significant shortening of the filter life.
This re-agglomeration begins immediately after the actual dispersion process in the compounder and occurs in the following aggregates and pipelines. Although mixing of the high concentrate from the side-flow with the main flow results in a lateral distribution of the re-agglomerates, they are not fragmented in the static mixer. Once formed re-agglomerates retain their size and must be filtered out, which quickly has a very negative effect on the efficiency of the process.
In addition, the low rotational speeds used also negatively impact the economy of the process because of the low throughputs associated therewith. However, for quality reasons low speeds are required in DE 40 39 857 A1. In addition, in particular for PA 6 according to Example 2, only a side-flow concentration of 4% by weight is suggested, which is diluted to a final concentration of only 0.6% by weight, which renders the entire extrusion system with associated peripherals, such as melt line, pumps etc. very big and expensive.
For good dispersion, the time of interaction of the polymer melt, in particular with generators of high shear rates such as kneading blocks, also plays a role, but also the shear rate, which is adjusted via the rotational speed of the screw. Thus a suitable screw design enables achieving a high shear rate, even at low rotational speed. This is superimposed with the rotational speed of the screw shafts. Neither DE 40 39 857 A1 nor WO 2012/168252 A1 achieve producing an acceptable end product also at high machine throughput via adjusting possible parameters. WO 2012/168252 A1 fully embraces the content of DE 40 39 857 A1. A further development of the dispersion and the degradation behavior was expressly excluded in the context of WO 2012/168252 A1. Full-Dull end products, which could be generated via backmixing in the melt mainflow, have not been investigated.
DE 10 2007 060 338 A1 discloses a further possibility of additizing via a twin-screw extruder, which can also be used in the side-flow. In this case, additives such as TiO2 are fed to the main extruder via a side extruder. Both the side extruder and partial sections of the main extruder have a defined conveying gap between the screw elements and an increased distance from the housing wall in order to prevent compaction of the TiO2, in particular during the feed to the twin-screw extruder. However, DE 10 2007 060 338 A1 does not disclose any information regarding the rotational speeds, throughputs, shear rates or polymer end product qualities used. Neither backmixing with a main flow of melts nor any end products such as Semi-Dull or Full-Dull modified PA 6 are described. DE 10 2007 060 338 A1 relates exclusively to feeding pigments to the dispersion process while avoiding compaction effects during the feed.
US2014080951A1 describes a process for producing a thermally conductive composition, which comprises the steps of introducing a thermally conductive polymer into an extruder, introducing a thermally conductive filling material into the extruder, forming a melt blend containing the polymeric material and the thermally conductive filling material and extruding the melt while coextruding an extrudate, wherein the extruder contains an inlet for feeding the polymeric material into the extruder and an extruder screw, the extruder screw having a section of kneading elements located downstream of the inlet and a section with part mixing elements, screw mixing elements, turbine mixing elements, stirring elements, or a combination of two or more of the mentioned elements, which are arranged downstream of the kneading elements. The teaching also describes a thermally conductive composition, which contains thermally conductive fillers, including titanium oxide, and which is produced by the mentioned process.
US2015184055A1 is a continuation-in-part of application US2014080951A1 and describes a thermally conductive filler composition containing a blend of a boron nitride, a graphite, or a combination thereof, a talc, and optionally a silane. The teaching describes, for example, optimized weight ratios of the composition of the individual constituents and embodiments of silanes, which improve the interaction of the fillers with the polymer to be filled. The application also mentions additives added to the fillers, one of these additives being titanium oxide. The application also describes a method for producing a thermally conductive extrudate and the use of the thermally conductive extrudates.
EP0410649A1 describes a method for producing a high molecular weight polyamide from a lower molecular weight polyamide polymer precursor by built-up polymerization, wherein the polyamide polymer precursor is a dicarboxyl-terminated polyamide and the further polymerization is carried out in an extruder in the presence of an additive which may be the same or different diamine used to make the polyamide polymer precursor. The application also outlines the extrusion step in the extruder for making the disclosed polyamide using a twin-screw extruder divided into the sections feeding and compression, mixing, reaction zone with agitation, degassing, and further compression with agitation and spinning.
WO2014141978A1 describes a method for producing a polyamide resin by polycondensation of a polyamide oligomer, which has a relative viscosity of 1.1 to 1.3 and a water content of 3 percent by weight or less, by melt kneading using a toothed twin-screw co-extruder having one or more pressure equalizing ports and one or more vacuum supply ports, wherein in the extruder, a pressure-reducing fitting, which is for example a counter-rotating screw or a sealing washer fully expanding in diameter of the twin-screw extruder, is arranged for the outlet of the water, and wherein the pressure reducing component is arranged closer to the input part of the twin-screw extruder than to the vacuum supply ports, and wherein a spatial region of 30% or less of the entire length of the twin-screw extruder is a vacuum region subjected to a pressure of 300 Torr or less.
WO2014179035A1 describes a method for mixing additives into a polyamide polymer which includes the steps of branching a partial flow of polymerized polyamide from a continuous polyamide production plant in the upstream direction to obtain a polyamide partial flow, admixing an additive into the polyamide partial flow to obtain a polyamide-additive secondary mixture, and recycling the polyamide-additive secondary mixture in the downstream direction into the main polyamide flow, wherein the branched polyamide partial flow in the polymerized polyamide has a water content of 0.1 to 0.3%. The teaching also describes a polyamide production plant as a polyamide production system, which includes a lateral conduit in the upstream direction with a mixing chamber, so that a polyamide partial flow can be branched off, wherein the mixing chamber is usable for metering an additive into the polyamide partial flow, and wherein the return line for the polyamide partial flow with the admixed additive is arranged in the downstream direction but upstream of an extruder located downstream thereof.
EP0410650A1 describes a method for producing a polyamide prepolymer having an average molecular weight of 3,000 to 5,000 g/mol, the prepolymer being obtainable by condensation of solid nylon salts prepared from a monomeric dicarboxylic acid and a monomeric diamine in stoichiometric composition, and wherein the condensation process is carried out in an extruder in the presence of a catalyst under the action of heat and vacuum. In one embodiment of the method, the extruder includes a powder feed zone, a powder transfer zone, a seal zone, a further sealed melt zone, a vacuum zone to remove the volatile condensation products under vacuum, and a pump and count zone in which a polyamide melt is obtained which can be further condensed for spinning.
WO2008045754A2 describes a method for providing a thermoplastic multicolor composition which includes the method steps of feeding and mixing a base polymer with additives into a two-shaft extrusion cylinder and with a first mixing zone in which a composition base material is prepared under high shear, admixing a plurality of fibrous materials into the composition base material in a second, low-shear mixing zone of the extrusion cylinder, further admixing a controlled amount of one or more colorants into the extrusion cylinder, and pressing the extruded material into an extrusion die to obtain an extruded product with a multicolor surface. The resulting products are used in particular for the production of plastic products with a wood-imitating surface.
According to EP 0 852 533 B2, a high torque density of greater than 11 Nm/cm3 is used with a simultaneously high screw speed of at least 800 rpm with a Da/Di (outer diameter/inner diameter) of 1.5 to 1.6. The torque density per screw is defined as the quotient of the torque of the single screw and the cube of the axial distance of the two screws of the twin-screw extruder (Md/a3). In accordance with the approximate formula given in EP 0 852 533 B2 for calculating the mean shear rates
this results in an approximate average shear rate of well over 150 s−1. The residence time in the extruder is reduced, which should then simultaneously lead to a low polymer degradation. For this purpose, a very high torque density is required with simultaneously adapted screw configuration in order to achieve a high throughput. However, specific polymers and their qualities are not addressed. Likewise, no backmixing with a main flow of polymer is disclosed. As with all documents described above, no non-extracted intermediate was processed here, only the finished extracted end product. Since the field of application of the disclosed invention is conventional masterbatch production, the processing of non-extracted PA 6 intermediate was also not relevant to this application. Consequently, no particle sizes or other quality features are mentioned for a back-mixed product, in particular not for non-extracted PA 6. The description of the features essential to the invention relates above all to the continuous mixing in the solids conveying field, to the grinding of coarse-grained bulk materials to powder and to the conventional masterbatch production.
The peculiarity of the addition of non-extracted PA 6 is that the high proportion of low molecular weight substances influences the rheological properties. Thus, for example, admixtures of substances in the small to very small percentage range, in particular in the case of polymers, can influence the physical properties. In the case of non-extracted PA 6, the amount of low molecular weight substances is even in a proportionately very high range. Accordingly, it is unpredictable how the non-extracted material will behave during the addition of additives, e.g. in terms of dispersion, re-agglomeration and polymeric degradation.
Based on the described prior art and the disadvantages therein, it was the object of the present invention to provide, specifically for non-extracted PA 6, an improved method and apparatus for additizing a polymer melt, which allow high additive concentrations, in particular of TiO2, in the side-flow, and which allow generating a high quality end product after re-dilution also for Full Dull applications with fast product changes without viscosity reduction and at high throughput, and thus have a much higher efficiency also owing to a comparatively better product.
This object is achieved by a method and a device according to the independent claims. Further advantageous embodiments of the invention can be found in the dependent claims.
The unexpectedly good end results of the method according to the invention may, inter alia, also be achieved in conjunction with the composition of the non-extracted intermediate product, which usually does not find use in a compounding process, and the resulting rheological properties.
The process sequence will be described below with reference to
Subsequently, the mixture is fed to a further melt pump (not shown in
In contrast to the configuration described in DE 40 39 857 A1, the additive is not introduced into the first extruder housing, but downstream via a side feeder. The advantage of the use according to the invention of a side feeder is that the rotational speed of the side feeder screws can be set separately from the speed of the compounder. In the process described in DE 40 39 857 A1, this is not possible. Bonding, as described for the process of “Chemiefaser/textile industry 1 (1986) 24 et seq.” does not occur. A supply of the additive in the first housing of the extruder, as described in DE 40 39 857 A1, is thus not required.
In addition, it has surprisingly been found that it is also possible to dispense with a side-feeder in an embodiment as described in DE 10 2007 060 338 A1. An elaborate grinding of screw elements, as found necessary in DE 40 39 857 A1, or the use of a conveying gap to prevent compacting effects during feeding, as disclosed in DE 10 2007 060 338 A1, is surprisingly not required. Thus standard feed equipment can be used, which further increases the efficiency of the process.
Since the new method uses a melt charge, the torque density in the disperser (5) is small. It is preferably less than 10 Nm/cm3. The mean shear rates, calculated according to the above-mentioned approximation formula from EP 0 852 533 B2, are significantly greater than 150 s−1 at a ratio Da/Di of 1.48 present in the examples below. Preferably, in the dispersing device (5) an average shear rate calculated from the approximation formula of 150 to 1800 sec−1, more preferably from 250 to 1500 sec−1, most preferably from 350 to 1200 sec−1 is used.
The additive concentration in the melt side-flow (4) prior to back-mixing with the main melt flow (3) is preferably 10-30 wt. %, more preferably 14-25 wt. %, most preferably 17-22 wt. %.
Preferably, the additive concentration in the main melt flow (3) or the main melt side-flows (7, 8) after admixing the melt partial flow (4) is 0.03 to 3 wt. %, particularly preferably 1.5 to 2.3 wt. %, most preferably 1.7 to 2.0 wt. %. The produced product is preferably a Full Dull product (in the case of PA 6 corresponding to 1.7-1.8 wt. % of TiO2).
The maximum size of the additive particles, in particular for the case of TiO2 particles, in the back-mixed end product is preferably 5 μm, more preferably 3 μm.
The construction of a dispersing device (5) according to the invention and its melt supply and discharge is shown by way of example in
Examples of partially permeable conveying elements are shown in the drawings 4 to 6 of the patent application WO2014141978A1.
The mentioned sequence of the five areas with the treatment zones is predetermined according to the invention, but the exact screw structure can be adapted in detail to the respective polymer and additive properties as well as the desired additive loading by means of the abovementioned options.
In the examples, a TiO2 product with the name “Hombitan LO-CR-S-M W/O Si” from the company Sachtleben was used.
The comparative example is a commercially available Full Dull PA 6 product from LiHeng (Changle) Polyamide Technology Co., Ltd., which is used by LiHeng as a raw material for various yarns. It is a finished, extracted PA 6 polymer in which the low molecular weight fractions were removed by extraction prior to the additizing. This example serves for comparing the TiO2 particle size distribution.
Table 1 summarizes the experimental data for the preparation of the examples in the compounder.
The samples of the examples and the comparative example were characterized by Scanning Electron Microscopy (SEM) and viscometry.
In the SEM investigations, the samples were measured by scanning electron microscopy and evaluated by means of the statistical evaluation method “x50”. A description of the statistical evaluation “x50” can be found in “The Science and Engineering of Granulation Processes”, Jim Litster, Bryan Ennis, Springer Science+Business Media Dordrecht, 2004, ISBN 978-1-4020-1877-0, page 17. For the present investigations, an evaluation based on the volumetric distribution was used, which accordingly generates a higher weighting of the larger particles relevant for the clogging of melt filters than a number-based distribution. The values contained in the following Table 2 correspond to particles that are passed through in a cumulative volume-based analysis of 50% of the particles.
The actual electron microscopic measurement was carried out as follows:
For sample preparation, the chips were fixed in a sample holder and subjected to the plasma etching process. To then capture the chips, four chips were fixed in the sample holder and three images per chip or twelve images per sample were made.
The SEM measurement detects particles larger than 80 nm on a viewing area of at least 0.0074 mm2. This results in a total particle number of about 500-1000 particles. The measured particles are then divided into parts >0.3 μm/>0.6 μm/>1.0 μm and evaluated as described above by means of the static evaluation x50.
The relative viscosities were measured according to DIN EN ISO 307. The measurement results are summarized in Table 2.
As shown in Table 2, the novel process provided an excellent particle size distribution as compared to the commercial product. Thus, the product produced by the new process is absolutely comparable to the commercial product from a conventional production.
The relative viscosities of the samples of Example 1 and Example 2 were 2.29 and 2.30. In addition to the comparative example of Table 2, which represents the commercial product, a blank sample was taken from the non-extracted, i.e., non-extruded starting material examined. This non-extruded and non-extracted starting material had a relative viscosity of 2.25. That is, no polymeric chain degradation has occurred during the compounding process.
The measured maximum TiO2 particle sizes are usually less than 2 μm after back-mixing for the Full-Dull end product. Considering that a much coarser filtration is used in a PA 6 production process, e.g. 10 μm, this is an excellent and surprising result. The use of an enhanced filtration, for example of the type that is usually essential for a Full Dull end product to obtain an acceptable end product is no longer necessary according to the new method. That is, the otherwise commonly occurring harmful re-agglomeration behind the compounder that results in particle sizes capable of clogging production filters of fineness customary in production does not occur.
The scanning electron micrographs show comparable to better values than the commercial Full Dull product, which was produced by the conventional process with TiO2 addition in the polymerization process.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2015 116 724.7 | Oct 2015 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2016/067959 | 7/27/2016 | WO | 00 |
