Patent Application
20090093606
Shape memory polymers, after being strained, can restore their original shape upon heating above a certain temperature (i.e., switching transition temperature).
Though there have been many research papers on shape recovery polymers, the study on shape memory fibers is at its initial stage. Compared with shape memory polymer bulk, shape memory polymer fibers have outstanding mechanical properties because of their molecular orientation.
Several polymer systems have been reported possessing shape memory properties such as trans-polyisoprene (TPI), poly(styrene-co-butadiene), polynor bornene, shape memory polyurethane, etc. The most representative one is shape memory polyurethane because of its easy control of critical temperature. The molecular mechanism of the shape memory effect of the block copolymers is the formation of phase segregated morphology (hard segment phase and soft segment phase). They fall into three groups by the different switching transition temperature, the first is the soft segment melting transition temperature, and the second is a mixed glass transition temperature.
The present invention relates to methods for synthesizing shape memory polyurethane. The shape memory polyurethanes can be synthesized via solution polymerization or bulk polymerization. Following synthesis, the polyurethane can be further treated to provide shape memory fibers suitable for use in smart textiles and apparels, biomedical materials, high performance sensors, actuators, filtration media, etc. Further treatment to the polyurethane can include wet spinning, dry spinning, reaction spinning, melt spinning, and electro spinning.
These and other features, aspects, and advantages of the apparatus and methods of the present invention will become better understood from the following description, appended claims, and accompanying drawings where:
The following description of certain exemplary embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. Throughout this description, the term “solution polymerization” shall refer to a process for producing shape memory polyurethane in solvent. “Bulk polymerization” shall refer to the conversion of monomer into a polymer without the acid of solvent. “Difunctional” shall refer to a compound having 2 reactive sites in each molecule.
Now, to
Suitable solvents can be selected from the group consisting of N,N-dimethylformamide (DMF), Dimethylformamide, N,N-Dimethylacetamide, 1-methyl-2-pyrrolidinane, and methyl sulfoxide.
The mixture is then heated 205 between 60° C. to about 90° C. for a period of between about 1 to about 4 hours. A molecule extender is then added to the mixture 207.
Suitable molecule extender can be selected from the group consisting of 1,3-propanediol, 1,4-butanediol, 1,2-ethanediol, 4,4′-dihydroxy biphenyl, 2,2-Bis(hydroxymethyl)propionic acid, N-Bis(2-hydroxyethyl)-isonicotinamide, N-methyldiethanolamine, Bisphenol A ethoxylate, 1,2-Diaminoethane, 1,2-Diaminopropane, and mixtures thereof. Heat is then applied to the mixture, between about 60° C. to about 90° C., for a period between 1 to about 4 hours 209. In one embodiment, during heating, solvent is continually added to the mixture.
The resultant shape memory polymer in the above methods is then further treated to produce shape memory fibers. Further treatments include wet spinning, dry spinning, melt spinning, reaction spinning, and electro spinning.
In one embodiment, following solution polymerization the polymers are further treated by wet spinning. During wet spinning, the solution solid concentration is adjusted to 20 to about 35 wt % and a viscosity of 50 to about 150 Pa·S using an appropriate solvent, such as N,N-dimethylformamide(DMF), Dimethylformamide, N,N-Dimethylacetamide, 1-Methyl-2-pyrrolidinone, or Methyl sulfoxide. This solution is extruded through orifices horizontally in a coagulation water bath to diffuse out the solvent with a given spinning speed. After passing the water bath, the filaments are taken up to apply subsequent processes including water bath for further removal of residual solvent and drying with hot air of 40 to about 80° C. Then, the filaments are wound up at a given velocity between 20 to about 100 m/min. In order to release the internal stress caused by the velocity difference among rollers in drying and winding process, the original shape memory fibers were treated with heating aftertreatment including stretching on hot rollers at 80 to about 150° C., or steaming at 100° C. at 400 kPa.
In another embodiment, following solution polymerization, the polymers are further treated by dry spinning. During dry spinning, the spinning solution solid concentration is adjusted to 25 to about 30 wt %. It is put through a spinneret by a spinning pump from the head pipe. After that, it is passed through a spinning tube which is about 5 to about 9 m long. Simultaneously, hot air is supplied to evaporate the solvent. The tube was heated to up to between 280 to about 340° C. in the upper and between 140 to about 180° C. in the lower. The solvent is recovered. The spinning speed is from 200 to about 1000 m/min. If diamines are used as extenders urea-urethane groups are formed and high mechanical properties fibers with good heat stability are obtained.
In another embodiment, following bulk polymerization, the polymers are further treated by melt spinning. During melt spinning, shape memory chips are dried at 60 to about 90° C. and 0.08 MPa for 6 h so that the chips moisture content reaches below 100 ppm. The shape memory fibers are spun in highly pure nitrogen environment using a 20 mm single screw extruder. The temperatures at the first zone, second zone, third zone, forth zone, extruder head, spinning pack, melt pipe and pump are 175 to about 190° C., 200 to about 215° C., 203 to about 218° C., 205 to about 220° C., 207 to about 222° C., 207 to about 222° C., 207 to about 222° C., 207 to about 222° C., respectively. Laminar air temperature can be 22° C. Winding speed is 100 to about 800 m/min. Overfeed speed is about 5 to about 40 m/min correspondingly.
In another embodiment, the polymers are further treated by reaction spinning. During reaction spinning, since the reaction of NCO with polyether or polyester diol or molecule extender only take several second with catalyzer, the shape memory polyurethane polymerization and the spinning process are combined. It is especially effective for the shape memory fiber with slight cross-linking to obtain higher mechanical properties by a triol or triamine because a relatively strong skin from the cross linked polyurea urethane is formed by immediate NCO-amine reaction. The shape memory fiber reaction spinning is as follows: (1) with highly pure nitrogen gas protection, mix a difunctional polyester or polyether diols (molecular weight from 500 to 30000) with excessive difunctional isocyanate to form a mixture at 70 to about 90° C. and to react for 1 to about 2 hour; (2) the pre-polymer including a muti-ol is extruded into a spin baths of diamines with portions of tramines to form shape memory fibers; (3) the fibers are further hardened in hot water or diamine/alcohol solutions. The spinning speed is from 100-500 m/min. The alcohol can be Trimethyolpropane, Dlycerin, 1,2,6-Hexanetriol, Trimethylolethane, Pentaerythritol, Pentane-1,2,3,4,5-pentol, Mannitol, or Sucrose. The diamine can be N,N-Bis(2-hydroxyethyl)-isonicotinamide, N-methyldiethanolamine, 1,2-Diaminoethane, 1,2-Diaminopropane or their mixtures. The triamine can be Diethylene triamine.
For electro spinning, shape memory polyurethanes can be prepared both by solution polymerization and bulk polymerization. For shape memory polyurethane prepared by solution polymerization, its solid concentration is diluted to 3 to about 12 wt % using a suitable solvent. The solvent is selected from such as N,N-dimethylformamide(DMF), Dimethylformamide, N,N-Dimethylacetamide, 1-Methyl-2-pyrrolidinone, or Methyl sulfoxide. For shape memory polyurethane prepared by bulk polymerization, the spinning melt is obtained by heating the polymer between 180 to about 230° C. During spinning, a controlled external electric field in the range of 12 KV to about 25 KV is imposed on the polyurethane solution or melt. The distance between the grounded aluminum sheet collector and the needle tip is 15 cm. The spinning solution flow speed is in the range of 0.04 ml/min to about 0.1 mm/min.
To get high dimension stability, the fibers are steamed in a vessel or treated in an oven at an elevated temperature in the relaxed state to remove internal stress. Generally, the fibers are steamed in a vessel for 10 minutes or treated in an oven at 130° C. for 10 minutes at the relaxed state.
The shape memory fibers prepared via the spinning methods have a tensile strength of more than 0.9 cN/dtex and elongation break at 350 to about 500%. The shape fixity ratio is more than 80% and shape recovery ratio higher than 85% measured using an Instron 4466 equipped with a thermal chamber. The switching transition temperature (Ttrans) required for specific applications can be tuned from below zero to 100° C. by slight variation of the chemical compositions. The fiber initial modulus is also adjustable from 0.08 to about 0.3 cN/dtex by variation of the chemical compositions or spinning technology. The shape memory fibers prepared by electro spinning have a controllable diameter between 50 to about 700 nm by regulating the voltage, solid concentration, spinning speed, and melt viscosity.
The prepared shape memory fibers are suitable for user in a number of industries, for example, textiles. At a temperature below the switching transition temperature when creases usually develop, the original wrinkle-free textile can be restored once it is re-heated above the switching transition temperature. The un-deformed textiles shape can be reserved when it is cooled down to a temperature below the switching transition temperature. More important, the prepared textile has a controllable shape relying on the external stress and the shape can be fixed completely according to the external conditions.
The shape memory polyurethane was synthesized using poly(butanediol-adipate) as the soft segment, and diphenylemethane-4,4′-diisocyanate and 1,4-butanediol as the -hard segment by solution polymerization. The filament was precipitated in the coagulation bath. The spinning conditions are listed in Table 1. The fiber was steamed for 10 minutes at the relaxed state to remove the internal stress. The prepared shape memory fiber properties are tabulated in Table 2
The shape memory polyurethane was synthesized using poly(butanediol-adipate) as the soft segment, and diphenylemethane-4,4′-diisocyanate and 1,4-butanediol as the hard segment by solution polymerization. The filament was precipitated in the hot air in a heated tube. The spinning conditions are tabulated in Table 3. The fiber was treated in an oven at 130° C. for 10 minutes at the relaxed state to remove the internal stress. The prepared shape memory fiber properties are tabulated in Table 4.
The pre-polymer was prepared using poly(butanediol-adipate) as the soft segment while glycerin and diisocyanate as the hard segments. The spinning bath was ethylene diamine with diethylene triamine. The final hardening media was diamine solution. The spinning speed was 100 m/min. The spinning conditions are listed in Table 5. And the prepared shape memory fiber properties are tabulated in Table 6.
The shape memory polymer was prepared using poly(ε-caprolactone) diol (PCL) as the soft segment, and diphenylemethane-4,4′-diisocyanate and 1,4-butanediol as the hard segments, by bulk polymerization. The spinning conditions are listed in Table 7. And the prepared shape memory fiber properties are tabulated in Table 8.
PCL-4000 based shape memory polyurethane with 25 wt % hard segment content was synthesized by bulk polymerization technology. The obtained polyurethane number average molecular weight was 18,000 measured by a high performance liquid. The polyurethane was dissolved in DMF to prepare spinning solution. The spinning conditions are listed in Table 9.
Having described embodiments of the present system with reference to the accompanying drawings, it is to be understood that the present system is not limited to the precise embodiments, and that various changes and modifications may be effected therein by one having ordinary skill in the art without departing from the scope or spirit as defined in the appended claims.
In interpreting the appended claims, it should be understood that:
a) the word “comprising” does not exclude the presence of other elements or acts than those listed in the given claim;
b) the word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements;
c) any reference signs in the claims do not limit their scope;
d) any of the disclosed devices or portions thereof may be combined together or separated into further portions unless specifically stated otherwise; and
e) no specific sequence of acts or steps is intended to be required unless specifically indicated.
