Patent Grant
11255025
The present invention relates to a spinning nozzle device for manufacturing a high-strength fiber, and more particularly to a spinning nozzle device for manufacturing a high-strength fiber that optimizes the heating method for the spinning region in the process of melt-spinning a thermoplastic resin through spinning nozzles to heat up the melted fiber coming out of the spinning nozzles to a temperature above the temperature of the pack body during a short period of time without occurrence of thermal degradation, so it is possible to control the molecular entanglement structure in the melted polymer of the thermoplastic resin without deterioration of the molecular weight caused by an instantaneous heat treatment at high temperature, resulting in the enhanced drawability of the fiber and hence the improved mechanical properties such as strengths and elongation, to reduce the melt viscosity (nozzle shear pressure) of the fiber during the spinning process while utilizing the existing processes for melt spinning and drawing, allowing the spinning of a high-viscosity resin, and to lower the cooling rate of the fiber to reduce the spinning tension (orientation), additionally improving the spinning speed (production rate) and thus realizing a large-quality production of high-strength fibers at a low cost.
As for the PET (Polyethylene terephthalate) fibers commercially available, the reported maximum strength is about 1.1 GPa and the practical maximum strength is no more than 3 to 4% of the theoretical strength and only a third of other high-strength fibers' (e.g., about 2.9 GPa of ultimate performance para-aramid (Kevlar) fibers). Hence, there is a limit to the application of the PET fibers to the industrial textile materials requiring ultimate performances other than general clothing or some household or industrial fiber materials (e.g., tire cord).
As mentioned above, compared to liquid crystal polymers (LCP) like PBO (poly(p-phenylene-2,6-benzobisoxazole, Zylon) and para-aramid (Kevlar) fibers, non-LCP thermoplastic polymer fibers such as PET and nylon fibers display lower strength and have no ultimate increase in their actual strength with respect to the theoretical value. This results from the difference of behaviors in the formation of structures when the resin is processed into fibers.
That is, the liquid crystal polymers (LCP) are capable of forming a structure of liquid crystals while in the liquid phase. Under a proper shear stress, they have just a small difference in entropy of the fiber structure before and after spinning and form a fiber structure having a considerably high degree of orientation and crystallinity, realizing a production of high-strength, high-performance fibers.
By the contrast, non-LCP thermoplastic polymers such as PET and nylon fibers have a complicated structure with polymer chains entangled in the form of non-crystalline random coils in the liquid phase. Hence, even under high shear stress at the spinning nozzles and then with high draw ratio (e.g., draft and drawing ratio), they are relatively hard of having a complete orientation-induced crystallization (i.e., high strength) due to the entangled random-coil structure, resulting in a large difference in the entropy of the fiber structure before and after the spinning process.
Despite the structural disadvantages of the general thermoplastic polymers, the development of thermoplastic polymers with higher strength may expand the market for the applications of thermoplastic polymers and bring about a great ripple effect. Therefore, many studies have recently been made on the methods of maximizing the properties and increasing the critical performances of the general PET fibers as led by the Japanese textile industry.
For example, there are reported studies on the manufacture of a high-strength fiber using an ultrahigh-high-molecular-weight PET resin [Ziabicki, A., “Effect of Molecular Weight on Melt Spinning and Mechanical Properties of High-Performance Poly(ethylene terephthalate) Fibers”, Text. Res. J., 1996, 66, 705-712; Sugimoto, M., et al., “Melt Rheology of Polypropylene Containing Small Amounts of High-Molecular-Weight Chain. 2. Uniaxial and Biaxial Extensional Flow”, Macromol, 2001, 34, 6056-6063], and the maximization of orientation using a coagulation bath technique to the melt spinning [Ito M., et al., “Effect of Sample Geometry and Draw Conditions on the Mechanical Properties of Drawn Poly(ethylene terephthalate)”, Polymer, 1990, 31, 58-63].
However, those studies are not available in the practical uses due to their limits in the workability and productivity with respect to the effect of enhancing the properties of fibers in consideration of the laboratory-scaled approach to the development of high-strength PET fibers.
In Japan, there has recently been a study on the approach to enhancing the strength of the existing fibers from 1.1 GPa to 2 GPa using a general thermoplastic polymer such as PET or nylon based on the melt spinning process without raising the production cost twofold or more.
Furthermore, the fields under research and development for the purpose of being applied to the tire cords most consumed as an industrial fiber and put into practical use are the melted structure control technology, the molecular weight control technology, the drawing/annealing technology, and evaluation/analysis technology.
Particularly, the melted structure control technology is an approach to the conception of controlling the molecular entanglement structure in the melted polymer and identifying the structure control and behavior in non-oriented amorphous fibers to realize the high strength of the PET fibers, rather than to the conception of controlling the behavior of forming a fiber structure through the molecular orientation and crystallization of the existing solidified fibers to impart high strength to the fibers.
Accordingly, there is a study on the manufacture of high-strength PET fibers using the design of a spinning nozzle device, a laser heating, a supercritical gas, a coagulation bath, etc. as a means for controlling the molecular structure in the melt spinning process.
In particular, an example of the conventional spinning nozzle design for the melt spinning process is a technique for applying a local heating in the vicinity of the spinning nozzle in the production of high-strength PET fibers, which is a local heating method that involves applying a heat directly from under the spinning nozzle as shown in
More specifically, the spinning nozzle apparatus used for the melt spinning process includes a pack-body heater 300 with a heat source having a temperature of 100 to 350° C., a pack body 200 held to the pack-body heater 200, a spinning nozzle 100 fixed to the pack body 200, and a lower plate 500 and a retainer 600 sequentially installed on the top of the spinning nozzle 100. The melted thermoplastic resin is fed into the spinning nozzle 100 through the retainer 600 and the lower plate and spun through spinning nozzle holes 111 of the spinning nozzle 100.
The fiber 112 formed after the spinning process is passed through a 20-200 mm annealing heater 400 that is an electric heater for applying a heat in the temperature range from room temperature to 400° C. to the fiber uniformly from a constant distance, which realizes a high-efficiency heat transfer at a lower cost.
But, the local heating method for the fiber 112 with the annealing heater 400 is not for heating the fiber but for warming the fiber to maintain the uniform temperature of the spinning nozzle holes 111 at the lower part of the spinning nozzle 100, minimizing the temperature deviation of the spinning nozzle holes 111, so it is effective only to improve the spinning workability and quality rather than to uniformly apply a heat to the fiber 112 as the fiber 112 is far apart from the annealing heater 400.
Another conventional spinning nozzle apparatus for a local heating in the vicinity of the spinning nozzle in the melt spinning process involves irradiating a CO2 laser beam directly from under the spinning nozzle with the spinning orifice having a micronized diameter to produce a high-performance PET fiber with the post-drawing strength of 1.68 GPa (13.7 g/den) and elongation of 9.1% [Masuda, M., “Effect of the Control of Polymer Flow in the Vicinity of Spinning Nozzle on Mechanical Properties of Poly(ethylene terephthalate) Fibers”, Intern. Polymer Processing, 2010, 25, 159-169].
In this regard,
The laser-based heating directly from under the spinning nozzle 100 may have an effect of heating a specific region of the fiber 112, but with the difficulty of being applied to the practical spinning nozzle 10 that has scores to scores of thousands of spinning nozzle holes 111.
In an attempt to improve the problems with the conventional method of applying a local heating directly from under a spinning nozzle in the process of manufacturing of a high-strength fiber, the inventors of the present invention have found it out that a heat transfer method can be optimized by locally applying a heat in the vicinity of the spinning nozzle holes of a practical spinning nozzle to heat up the melted fiber coming out of the spinning nozzles to a temperature above the temperature of the pack body during a short period of time without occurrence of thermal degradation, so it is possible to control the molecular entanglement structure in the melted polymer of the thermoplastic resin without deterioration of the molecular weight caused by an instantaneous heat treatment at high temperature, resulting in the enhanced drawability of the fiber and hence the improved mechanical properties like strengths and elongation, to reduce the melt viscosity (nozzle shear pressure) of the fiber during the spinning process while utilizing the existing processes for melt spinning and drawing, allowing the spinning of a high-viscosity resin, and to lower the cooling rate of the fiber to reduce the spinning tension (orientation), additionally improving the spinning speed (production rate) and thus realizing a large-quality production of high-strength fibers at a low cost, thereby completing the present invention.
It is an object of the present invention to provide a spinning nozzle apparatus for manufacturing a high-strength fiber that uses the spinning orifice of a spinning nozzle disposed on the outside of a pack body in the melt spinning process of a thermoplastic resin and provides an optimized heating method for the spinning orifice.
In accordance with a first preferred embodiment of the present invention, there is provided a spinning nozzle apparatus for manufacturing a high-strength fiber that includes: a pack body 21; a pack body heater 22 installed on the outside of the pack body to provide a heat source for the pack body; a spinning nozzle 23 installed in the pack body 21 to spin a melted thermoplastic resin; and a retainer 24 and a lower plate 25 installed in the pack body to feed the melted thermoplastic resin into the spinning nozzle. The spinning nozzle 23 includes a fixation member 23b disposed on the inside of the pack body 21 and a spinning member 23c disposed on the outside of the pack body 21. The spinning member 23c disposed on the outside of the pack body has a plurality of spinning nozzle holes 23a for melt-spinning the thermoplastic resin to form a fiber. The spinning nozzle apparatus further includes a heating body 26 for heating the portion of the spinning nozzle holes 23a of the spinning member 23c to a temperature above the temperature of the pack body 21.
In the first embodiment of the present invention, the spinning nozzle 23 has an extension member 23d for maintaining the spinning member 23c apart from the fixation member 23b. The extension member 23d extends to a length of 10 to 500 mm from the bottom of the pack body 21 to position the spinning nozzle holes 23a of the spinning member 23c.
In the first embodiment of the present invention, the heating body 26 is installed in a ring form to surround the side wall of the spinning member 23c. Preferably, the bottom of the lower plate 25 is inserted in the spinning nozzle 23 and designed to extend to a boundary point between the extension member 23d and the spinning member 23c of the spinning nozzle 23 to induce the melted thermoplastic resin to an inlet of the spinning nozzle holes 23a. The spinning nozzle apparatus further includes a space member 27 between the inner wall of the fixation member 23b and the extension member 23d and the opposing outer wall of the lower plate 25, and an air passage hole 28 formed in the extension member 23d to provide a connection between the space member 27 and the outside.
In accordance with a second preferred embodiment of the present invention, there is provided a spinning nozzle apparatus for manufacturing a high-strength fiber that includes: a pack body 31; a pack body heater 32 installed on the outside of the pack body to provide a heat source for the pack body; a spinning nozzle 33 disposed on the outside of the pack body 31 having a plurality of spinning nozzle holes 33a for melt-spinning the thermoplastic resin to form a fiber; and a retainer 34 and a lower plate 35 installed in the pack body to feed a melted thermoplastic resin into a spinning nozzle 33. The lower plate 35 includes a first lower plate 35a disposed on the inside of the pack body 31, and a second lower plate 35b disposed on the outside of the pack body 31 and designed to be detachable from the first lower plate 35a. The spinning nozzle 33 is detachable from the bottom of the second lower plate 35b and disposed on the outside of the pack body 31.
The spinning nozzle apparatus further includes a heating body 36 for heating the portion of the spinning nozzle holes 33a to a temperature above the temperature of the pack body 31.
In the second embodiment of the present invention, the heating body 36 is installed in a form surrounding the lateral side and topside of the second lower plate 35b and the spinning nozzle 33. Preferably, a space member 37 is provided for passage of air between the bottom end of the pack body 31 and the heating body 36.
In accordance with a third preferred embodiment of the present invention, there is provided a spinning nozzle apparatus for manufacturing a high-strength fiber that includes: a pack body 41; a pack body heater 42 installed on the outside of the pack body to provide a heat source for the pack body; a spinning nozzle 43 being installed in the pack body 41 and having a plurality of spinning nozzle holes 43a for spinning a melted thermoplastic resin; and a retainer 44 (not shown) and a lower plate 45 (not shown) installed in the pack body to feed the melted thermoplastic resin into the spinning nozzle. The spinning nozzle apparatus further includes: a heating body 46 disposed under the spinning nozzle holes 43a of the spinning nozzle to heat up a fiber after a spinning process to a temperature above the temperature of the pack body 41; and an insulating layer 40 disposed between the spinning nozzle 43 and the heating body 46. The heating body 46 has a hole-type heating opening 46a or a band-type heating opening 46b arranged in a row for the passage of the fiber after the spinning process.
In the third embodiment of the present invention, the insulating layer 40 has a thickness of 1 to 30 mm, and the heating body 46 extending to a length of 1 to 500 mm from the insulating layer 40. Further, a heating region for the fiber is defined by the thickness of the insulating layer 40 and the extension length of the heating body 46.
In accordance with a fourth preferred embodiment of the present invention, there is provided a spinning nozzle apparatus for manufacturing a high-strength fiber that includes: a pack body 51; a pack body heater 52 installed on the outside of the pack body to provide a heat source for the pack body; a spinning nozzle 53 being installed in the pack body 51 and having a plurality of spinning nozzle holes 53a for spinning a melted thermoplastic resin; and a retainer 54 (not shown) and a lower plate 55 (not shown) installed in the pack body to feed the melted thermoplastic resin into the spinning nozzle. The spinning nozzle apparatus further includes a heating body 56 disposed in the vicinity of the spinning nozzle holes 53a of the spinning nozzle 53 to heat up the vicinity of the spinning nozzle holes 53a and a fiber after a spinning process to a temperature above the temperature of the pack body 51. The heating body 56 has a hole-type heating opening 56a or a band-type heating opening 56b arranged in a row for the passage of the fiber after the spinning process. The heating body 56 is in contact with the bottom of the spinning nozzle 53 or partially inserted in the bottom of the spinning nozzle 53.
In the fourth embodiment of the present invention, the bottom side of the spinning nozzle 53 is disposed at a distance of 1 to 300 mm from the bottom side of the pack body. The heating body 56 being in contact with the bottom side of the spinning nozzle 53 or partially inserted in the bottom of the spinning nozzle 53 to a insertion depth of 0 to 50 mm. The heating body 56 extends from the bottom side of the spinning nozzle 53 to an extension length of 0 to 500 mm. Further, a heating region for the fiber is defined by the insertion depth of the heating body 56 partially inserted in the bottom of the spinning nozzle 53 and the extension length of the heating body 56 from the bottom side of the spinning nozzle.
In the fourth embodiment of the present invention, the topside of the heating body 56 partially inserted in the bottom of the spinning nozzle 53 has a direct contact with or a gap from the facing surface of the spinning nozzle 53 facing the topside of the heating body 56. The insertion depth of the heating body 56 partially inserted in the bottom of the spinning nozzle 53 is defined as 50 mm to the maximum so that the heating body 56 performs a direct heating on the melted thermoplastic resin in the spinning nozzle 53 prior to a spinning process and an indirect heating on the fiber directly from under the nozzle body in a simultaneous manner.
In the third and fourth embodiments of the present invention, the hole- or band-type heating opening is preferably formed to have its inner circumference apart from the center of the spinning nozzle holes within a distance of 1 to 300 mm.
The spinning nozzle apparatus for manufacturing a high-strength fiber according to the present invention with the above-specified characteristic features is designed to optimize a heating method for the spinning region of a spinning nozzle in the melt spinning process. The heat transfer method is optimized by disposing the spinning nozzle holes of spinning nozzle commercially available on the outside of, directly under the pack body and heating the spinning nozzle holes with a heating body. In addition, an instantaneous heat treatment at high temperature is adopted to control the molecular entanglement structure in the melted polymer, which enhances the drawability of the thermoplastic resin and hence improves the mechanical properties such as strength and elongation.
The spinning nozzle apparatus for manufacturing a high-strength fiber according to the present invention makes the use of a heating device that employs the existing processes for melt spinning and drawing but offers a high energy efficiency with a simple structure, to effectively reduce the cooling rate of the fibers during the spinning process and enhance the spinning and drawing rates. This eventually lowers the initial investment cost and enables a large-quantity production of high-performance fibers at a low cost.
The spinning nozzle apparatus for manufacturing a high-strength fiber according to the present invention can also effectively reduce the viscosity of the melted resin in the spinning nozzle holes without deterioration of the molecular weight by adopting a heating device using the existing processes for melt spinning and drawing but offering a high energy efficiency with a simple structure. This increases the use cycle of the spinning nozzle, ensures a spinning process with a spinning nozzle with higher shear rate and higher L/D hole specification to improve the spinning workability and fiber quality, and particularly enables the spinning process for ultrahigh-viscosity resins which has never been realized before, to reduce the initial investment cost and produce high-performance fibers in large quantities at a low cost.
Based on high price competitiveness due to large-quality production and low cost and the control of various fiber properties, the spinning nozzle apparatus of the present invention is usefully available in the production of tire cords, interior materials for transportation including automobile, trains, aircrafts, ships, etc., civil engineering and construction materials, electronic materials, marine and military applications such as ropes and nets, and other clothing and household applications, including light-weighted sportswear and work clothes, military uniforms, furniture and interior materials, sports equipment, or the like, and hence promising market expansion for the wider range of applications.
Besides, the spinning nozzle apparatus of the present invention is applicable not only to the textile applications including PET long and short fibers, unwoven fabrics, etc. but also to the manufacture of films, sheets, molds, containers, or the like using those textile materials.
Hereinafter, the preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.
In the first embodiment of the present invention, the spinning nozzle 23 includes a fixation member 23b disposed on the inside of the pack body 21 and a spinning member 23c disposed on the outside of the pack body 21. The spinning member 23c disposed on the outside of the pack body has a plurality of spinning nozzle holes 23a for melt-spinning the thermoplastic resin to form a fiber. The spinning nozzle apparatus further includes a heating body 26 for heating the portion of the spinning nozzle holes 23a of the spinning member 23c to a temperature above the temperature of the pack body 21.
In the first embodiment of the present invention, the spinning nozzle 23 has an extension member 23d for maintaining the spinning member 23c apart from the fixation member 23b. The extension member 23d extends to a length of 10 to 500 mm from the bottom of the pack body 21, so the spinning nozzle holes 23a of the spinning member 23c are disposed on the outside of the pack body.
Namely, the spinning member 23c has a plurality of spinning nozzle holes 23a for melt-spinning a thermoplastic resin to form a fiber F. The extension member 23d extends to a length of 10 to 500 mm, more preferably 100 to 300 mm from the bottom of the pack body 21 so as to position the spinning member 23c and the spinning nozzle holes 23a on the outside of the pack body 21.
Further, the spinning member 23c of the spinning nozzle 23 has the heating body 26 for heating the portion of the spinning nozzle holes 23c disposed on the outside of the pack body 21. The heating body 26 is provided in the form of a ring and installed to surround the sidewall of the spinning member 23c.
Preferably, the bottom of the lower plate 25 is inserted in the spinning nozzle 23 and designed to extend to a boundary point between the extension member 23d and the spinning member 23c of the spinning nozzle 23 to induce the melted thermoplastic resin to an inlet of the spinning nozzle holes 23a.
In general, the pack body 21 is maintained at 50 to 350° C. with the pack body heater 22. Undesirably, the temperature of the pack body 21 lower than 50° C. maintains almost the resins hard rather than melted, and the temperature of the pack body 21 above 350° C. causes a rapid thermal degradation of the resin to deteriorate the properties of the fiber. Therefore, it is preferable to maintain the temperature of the spinning member 23c of the spinning nozzle 23 heated by the heating body 26 higher than that of the pack body 21. For example, the spinning member 23c of the spinning nozzle is preferably maintained in the temperature range of 350 to 700° C. when the temperature of the pack body 21 is 300° C. Accordingly, the heating temperature for the portion of the spinning nozzle holes 23a is higher than that for the melted resin in the pack body 21.
It is designed to minimize the heat transfer between the pack body 21 and the spinning nozzle 23. For this, a space member 27 is provided between the inner wall of the fixation member 23b and the extension member 23d of the spinning nozzle 23 and the opposing outer wall of the lower plate 25, and an air passage hole 28 is formed in the extension member 23d of the spinning nozzle 23 to provide a connection between the space member 27 and the outside.
Such a structure not only positions the spinning member 23c of the spinning nozzle on the outside of the pack body 21 but also allows the passage of air in the space member 27 between the spinning nozzle 23 and the lower plate 25, preventing a transfer of high heat from the heating body 26 to the pack body 21 through the spinning nozzle 23 and the resulting rise in the temperature of the pack body 21 at once. The elevation of the temperature may cause a deterioration of the raw material consisting of a thermoplastic resin, for example, polyester-based polymer resin in the pack body 21 and hence deteriorate the properties of the fiber product.
According to the spinning nozzle apparatus of the first embodiment, the melted thermoplastic resin induced into the spinning nozzle 23 through the retainer 24 and the lower plate 25 is spun through the spinning nozzle holes 23a to form a fiber F. After the spinning process, the fiber F is cooled down and subjected to the drawing and winding processes using a yarn texturing machine to form a high-strength thermoplastic polymer fiber.
In this regard, the heating body 26 instantaneously heats up the spinning member 23c of the spinning nozzle 23 exposed to the outside of the pack body 21 to a temperature above the temperature of the pack body 21 by at least 50 to 400° C., achieving a control of the molecular entanglement structure in the melted polymer being spun through the spinning nozzle holes 23a to improve the mechanical properties of the thermoplastic polymer fiber such as strength and elongation.
With such a construction that includes the extension member 23d designed to position the spinning member 23c of the spinning nozzle 23 on the outside of the pack body 21 and allows the passage of the external air in the space member 27 between the spinning nozzle 23 and the lower plate 25, it is possible to minimize the rise of the temperature caused by a heat transfer from the heating body 25 to the inside of the pack body 21 through the spinning nozzle 23 and thus to prevent a deterioration of the properties caused by the deterioration of the melted polymer in the pack body 21.
The lower plate 35 includes a first lower plate 35a disposed on the inside of the pack body 31, and a second lower plate 35b disposed on the outside of the pack body 31 and designed to be detachable from the first lower plate 35a. The spinning nozzle 33 is detachable from the bottom of the second lower plate 35b and disposed on the outside of the pack body 31. The spinning nozzle 33 disposed on the outside of the pack body 31 has a plurality of spinning nozzle holes 33a for melt-spinning the thermoplastic resin to form a fiber F. The spinning nozzle apparatus further includes a heating body 36 for heating the portion of the spinning nozzle holes 33a to a temperature above the temperature of the pack body 31.
For the detachable structure of the first and second lower plates 35a and 35b, the first lower plate 35a has a female screw member 38 and the second lower plate 35b has a male screw member 39, the male screw member 39 screws into the female screw member 38 to make the second lower plate 35b detachable from the first lower plate 35a. Preferably, the male screw member 39 of the second lower plate 35b has a hexagonal head member 39a that makes the rotation of the second lower plate 35b easier.
In the detachable structure of the first and second lower plate 35a and 35b, the top of the spinning nozzle 33 is inserted in the bottom side of the second lower plate 35b, and a bottom ring plate 30 being attached to the second lower plate 35b by means of the threads of a screw is used to fix the edge of the spinning nozzle 33 to the second lower plate 35b. The bottom ring plate 30 has an opening 30a to expose the spinning nozzle holes 33a of the spinning nozzle 33.
The outer wall and the topside of the second lower plate 35b and the spinning nozzle 33 are surrounded with the heating body 36 for heating up the portion of the spinning nozzle holes 33a of the spinning nozzle 33.
In general, the pack body 31 is maintained at 50 to 350° C. with the pack body heater 32. Undesirably, the temperature of the pack body 31 lower than 50° C. maintains almost the resins hard rather than melted and makes it difficult to spin the resins, and the temperature of the pack body 21 above 350° C. causes a rapid thermal degradation of the resin to deteriorate the properties of the fiber.
It is therefore preferable to maintain the temperature of the spinning nozzle holes 33a of the spinning nozzle 33 heated by the heating body 36 higher than that of the pack body 31. For example, the spinning nozzle holes 33a of the spinning nozzle 33 are preferably maintained in the temperature range of 350 to 700° C. when the temperature of the pack body 31 is 300° C. Accordingly, the heating temperature for the portion of the spinning nozzle holes 33a is higher than that for the melted resin in the pack body 31.
It is desirable to minimize a heat transfer between the pack body 31 and the heating body 36. For this, a space member 37 is provided between the pack body 31 and the heating body 36 to allow the passage of air. Further, the space member 37 makes the male screw member 39 of the second lower plate 25b exposed to the outside.
Such a structure prevents a transfer of high heat from the heating body 36 and the second lower plate 25b to the pack body 31 and the first lower plate 25a and the resulting rise in the temperature of the pack body 31 and the first lower plate 25a at once, where the elevation of the temperature may cause a deterioration of the raw material consisting of a thermoplastic resin, for example, polyester-based polymer resin in the pack body 21 and the first lower plate 25a and hence deteriorate the properties of the fiber product.
According to the spinning nozzle apparatus of the second embodiment, the melted thermoplastic resin induced into the spinning nozzle 33 installed on the outside of the pack body 31 through the retainer 34 and the lower plate 35 is spun through the spinning nozzle holes 33a of the spinning nozzle 33 to form a fiber F. After the spinning process, the fiber F is cooled down and subjected to the drawing and winding processes using a yarn texturing machine to form a high-strength thermoplastic polymer fiber.
In this regard, the heating body 36 instantaneously heats up the spinning nozzle 33 disposed on the outside of the pack body 31 to a temperature above the temperature of the pack body 31 by at least 50 to 400° C., achieving a control of the molecular entanglement structure in the melted polymer being spun through the spinning nozzle holes 33a to improve the mechanical properties of the thermoplastic polymer fiber such as strength and elongation.
With such a construction that allows the passage of the external air in the space member 37 between the heating body 36 and the pack body 31 and exposes the male screw member 39 of the second lower plate 35b through the space member 37, it is possible to minimize the rise of the temperature caused by a heat transfer from the heating body 36 to the pack body 31 and the second lower plate 35b and thus to prevent a deterioration of the properties caused by the deterioration of the melted polymer.
In the spinning nozzle apparatus of the second embodiment, the spinning nozzle 33 is detachable from the second lower plate 35b, which makes it easier and faster to replace the spinning nozzle 33 and clean the spinning nozzle holes 33a of the spinning nozzle 33 simply by separating the spinning nozzle 33 from the second lower plate 35b.
The spinning nozzle apparatus of the third embodiment further includes: a heating body 46 disposed under the spinning nozzle holes 43a of the spinning nozzle 43 to heat up a fiber after a spinning process to a temperature above the temperature of the pack body 41; and an insulating layer 40 disposed between the spinning nozzle 43 and the heating body 46. The heating body 46 has a hole-type heating opening 46a or a band-type heating opening 46b arranged in a row for the passage of the fiber after the spinning process.
The spinning nozzle 43 spins a melted thermoplastic resin through the spinning nozzle holes 43a to form a fiber F. After the spinning process, the fiber F is heated through the heating body, cooled down, and then subjected to the drawing and winding processes using an in-line texturing machine to produce a high-strength thermoplastic polymer fiber.
For this, the distance a1 from the inner circumference of the heating opening 46a to the center of the fiber F is preferably 1 to 300 mm, more preferably 1 to 30 mm. The hole-type heating opening 46a is capable of maintaining a uniform temperature at a same distance from its center in all directions.
A modified example of the heating opening 46a is illustrated in
Like the hole-type heating opening 46a, the band-type heating opening 46b is designed so that the distance a1 from the inner circumference of the heating opening 46b to the center of the spinning nozzle holes is preferably 1 to 300 mm, more preferably 1 to 30 mm.
Referring to
The temperature of the spinning nozzle 43 is the same as that of the pack body heater 41. The insulating layer 40 functions to reduce a heat transfer so that a high-temperature heat generated from the heating body 46 disposed directly under the spinning nozzle 43 is not transferred to the spinning nozzle 43. This can prevent the deterioration of the raw material consisting of a thermoplastic resin such as a polyester-based polymer resin in the spinning nozzle 43 and hence the deterioration of the properties of the fiber. In this regard, the material for the insulating layer 40 may be a known insulating material making an insulating effect, preferably an inorganic high-temperature/fire-resistant insulating material containing a glass- and ceramic-based compound.
The thickness a2 of the insulating layer 40 is preferably in the range of 1 to 30 mm that is the distance between the spinning nozzle 43 and the heating body 46. It is undesirable to have the thickness a2 greater than 30 mm, for example, because the fiber F formed after the spinning process through the spinning nozzle 43 is cooled down before the heat treatment using the heating body 46, which makes it difficult to effectively control the melted structure.
The extension length a3 of the heating body 46 is 1 to 500 mm from the bordering surface with the insulating layer 40. Accordingly, the heating region in which the fiber moves includes the thickness a2 of the insulating layer 40 and the extension length a3 of the heating body 46.
In other words, the heating body 46 of the third embodiment uses an indirect heating (e.g., radiation transfer) for the fiber F after the spinning process in such a way that while the fiber F is passing through the heating body 46, it moves a distance that includes the thickness a2 (1 to 30 mm) of the insulating layer 40 directly under the spinning nozzle 43 and the extension length a3 (1 to 500 mm) of the heating body 46 from the insulating layer 40.
At this time, the distance a4 directly from under the heating body 46 to the bottom surface of the pack body 41 is in the range of 1 to 50 mm so that the whole of the insulating layer 40 and part of the heating body 46 are disposed in the pack body 41. This realizes an indirect heating (e.g., radiation transfer) on all the fibers F immediately after the spinning process to improve the mechanical properties.
The heating region 50 including the heating body 46 and the insulating layer 40 as illustrated in the above-designed third embodiment of the present invention is available directly under the spinning nozzle 43 commercially available without a change of the design, lowering the initial investment cost and realizing a large-quantity production of high-performance fibers at a low cost.
In addition, the third embodiment applies an instantaneous heating on the whole fibers F discharged from the spinning process at high temperature uniformly from a constant distance with the heating body to control the molecular entanglement structure in the melted polymer, thereby the melt viscosity and enhancing the drawability, and uses the insulating layer 40 to prevent a high-temperature heat from being transferred to the spinning nozzle holes 43a of the spinning nozzle 43, reducing the deterioration of the properties caused by the deterioration of the melted polymer, improving the strength and elongation of the thermoplastic polymer fiber, and realizing a large-quantity production of high-strength fibers at low cost.
The spinning nozzle apparatus for manufacturing a high-strength fiber according to the fourth embodiment further includes a heating body 56 disposed in the vicinity of the spinning nozzle holes 53a of the spinning nozzle 53 to heat up the vicinity of the spinning nozzle holes 53a and the spun fiber as well to a temperature above the temperature of the pack body 51. The heating body 56 has a hole-type heating opening 56a or a band-type heating opening 56b or 56c arranged in a row for the passage of the fiber after a spinning process. The heating body 56 is in contact with the bottom of the spinning nozzle 53 or partially inserted in the bottom of the spinning nozzle 53.
In the fourth embodiment, the bottom side of the spinning nozzle 53 is disposed at a distance b1 of 1 to 300 mm from the bottom side of the pack body.
In the fourth embodiment, without an insulating layer right under the spinning nozzle 53, the heating body 56 is in contact with the bottom side of the spinning nozzle 53 or partially inserted in the bottom of the spinning nozzle 53 to an insertion depth b2 of 0 to 50 mm. The heating body 56 extends from the bottom side of the spinning nozzle 53 to an extension length b3 of 0 to 500 mm. Hence, a heating region 60 for the fiber is defined to include the insertion depth b2 of the heating body 56 partially inserted in the bottom of the spinning nozzle 53 and the extension length b3 of the heating body 56 from the bottom side of the spinning nozzle.
As shown in
Accordingly, the heating region 60 is provided to apply a first direct or indirect heating (e.g., heat conduction or radiation transfer) on the melted thermoplastic resin in the vicinity of the spinning nozzle holes 53a in the spinning nozzle 53 prior to the spinning process along the insertion depth b2 of the heating body 56 inserted in the bottom of the spinning nozzle 53 and the gap b4 and then a second indirect heating (e.g., radiation transfer) on the melted fiber F discharged from the nozzle body 52 yet not solidified after the spinning process along the extension length b3 (0 to 500 mm) of the heating body 56 extending from the bottom side of the spinning nozzle 53.
In the heating region 60 of the fourth embodiment, when the heating body 56 is inserted in the bottom of the spinning nozzle 53 to an insertion depth of 50 mm at the maximum, a heat transfer may occur to deteriorate the melted polymer in the spinning nozzle holes 53a of the spinning nozzle 53 and hence the properties of the fiber. Taking this problem into consideration, it is preferable to design such that the bottom side of the spinning nozzle 53 is disposed at a distance b1 of 1 to 300 mm from the bottom side of the pack body 51.
Due to the structure modification of the bottom in the spinning nozzle 53 commercially available, the heating region 60 of the fourth embodiment as described above is designed to realize an optimized double-heating thermal transfer method that involves a direct heat transfer to the vicinity of the spinning nozzle holes 53a of the spinning nozzle 53 and an indirect heating on the fiber F with the heating body 56 formed right under the spinning nozzle 53, making it possible to control the molecular entanglement structure in the melted polymer caused by the instantaneous heat treatment at high temperature and to enhance the drawability of the final thermoplastic polymer fiber, thereby improving the mechanical properties such as strength and elongation.
Accordingly, the fourth embodiment is modifying the bottom structure of the spinning nozzle 53 commercially available and immediately applicable to reduce the initial investment cost and to realize a large-quantity production of high-performance fibers at a low cost.
In the fourth embodiment, the heating body 56 is partially inserted in the spinning nozzle 53 to heat up the vicinity of the spinning nozzle holes 53a of the spinning nozzle 53, reducing the viscosity of the melted resin being spun through the spinning nozzle holes 53a, which may enhance the productivity according to the increase in the draw ratio and the spinning speed and enable the spinning of ultrahigh molecular weight resins due to the reduced viscosity of the melted resin particularly in the vicinity of the spinning nozzle holes 53a to realize a high strength of the fiber, while the spinning of ultrahigh molecular weight resins is impossible to carry out in the prior art due to high viscosity.
In the fourth embodiment of the present invention, the cross-sectional diagram taken by the line II-II of
More specifically, in the third and fourth embodiments of the present invention, the heating openings 46a, 46b, 46c, 56a, 56b, and 56c are designed to have the same number and structure of the spinning nozzle holes 43a and 53a of the spinning nozzles 43 and 53, so the fiber F discharged after the spinning process is locally heated while passing through the heating bodies 46 and 56, respectively. In particular, the hole-type heating openings 46a and 56a have the same structure of the spinning nozzle holes 43a and 53a of the spinning nozzles 43 and 53. But, their inner circumference is apart from the center of the spinning nozzle holes of the nozzle bodies at a distance of 1 to 300 mm so that it is possible to maintain a uniform temperature at a same distance from the center of the spinning nozzle holes 43a and 53a of the spinning nozzle 43 and 53 in all directions.
In addition, the band-type heating openings 46b and 56b have a linear structure with the halves almost exactly opposite one another, 180° apart on the spinning nozzle holes 43a and 53a of the spinning nozzles 43 and 53 and symmetric to each other at a distance of 1 to 300 mm from the center of the spinning nozzle holes 43a and 53a.
In this regard, it is designed to realize an indirect heating method that the fiber F is not in direct contact with the heating openings 46a, 46b, 46c, 56a, 56b, and 56c while passing through the heating openings after the spinning process. When the heating openings 46a, 46b, 46c, 56a, 56b, and 56c are large in size and apart from the spinning nozzle holes 43a and 53a of the spinning nozzles 43 and 53 at a distance less than 1 mm, it is highly likely to have the heating bodies 46 and 56 in contact with the fiber F, possibly causing contamination of the heating bodies 46 and 56 or the breakage of the fiber F to deteriorate the fiber quality and the workability and a risk of deteriorating the fiber F due to the exposure to excessive heat. When the distance between the heating openings 46a, 46b, 46c, 56a, 56b, and 56c and the spinning nozzle holes 43a and 53a of the spinning nozzles 43 and 53 is greater than 300 mm, a heat transfer to the fiber F is too insufficient to control the molecular entanglement structure in the melted polymer, undesirably reducing the effect of improving the properties.
When it comes to the structure of the spinning nozzle holes 43a and 53a of the spinning nozzle 43 and 53, as illustrated in
The pitch between the spinning nozzle holes 43a and 53a is at least 1 mm, and the cross-sectional shape of the spinning nozzle holes 43a and 53a is a circle as illustrated in the embodiments of the present invention but may also include any non-circular shape (e.g., Y, +, −, O, etc.). Further, a combination of at least two spinning methods such as sheath-core type, side-by-side type, sea island type, or the like may be available using a spinneret including spinning nozzles 10 and 50.
In the third and fourth embodiments of the present invention, the hole-type heating openings 46a and 56a of the heating bodies 46 and 56 are the same in the structure and the number as the spinning nozzle holes 43a and 53a of the spinning nozzles 43 and 53, so the opening structure may take any shape including circle, oval, rectangle, donut, etc.
In the spinning nozzle devices for manufacturing a high-strength fiber according to the first to fourth embodiments as described above, the temperature of the heating bodies 26, 36, 46, and 56 may be regulated with a general electric heat ray or a general heat medium in the same manner as that of the pack body heaters 22, 32, 42, and 52. Specific examples of the electric heat ray may include any one selected from a Cu— or Al-based cast heater, an electromagnetic induction heater, a near-infrared heater, a carbon heater, a ceramic heater, a PTC heater, a quartz tube heater, a halogen heater, and so forth.
The use of the spinning nozzle devices for manufacturing a high-strength fiber according to the first to fourth embodiments as described above in the production of a fiber F may be applied to any general thermoplastic resin, more preferably to any polymer resin vulnerable to heat. Moreover, the present invention is applicable to any spinning nozzle apparatus commercially available just with a minimum modification of the design, reducing the initial investment cost and realizing a large-quantity production of high-performance fibers at a low cost.
Specific examples of the thermoplastic resin as used herein may include nylon-, PP- or PE-based polymers as well as polyester-based polymers (e.g., PET (Polyethylene terephthalate), PBT (Polybutylene terephthalate), PTT (Polytrimethylene Terephthalate), PEN (Polyethylene naphthalate), etc.). The embodiments of the present invention are most preferably applicable to the production of polyester-based fibers. But they may also be applicable to the textile applications including PET long fibers and short fibers, unwoven fabrics, etc. and even to the manufacture of films, sheets, molds, containers, or the like using those textile materials.
In the spinning nozzle devices for manufacturing a high-strength fiber according to the first to fourth embodiments, in order to achieve the same object, it is necessary to optimize the retention time, flux, and shear rate of the melted polymer passing through the spinning nozzle holes 23a, 33a, 43a, and 53a of the spinning nozzles 23, 33, 43, and 53.
Preferably, the retention time of the melted polymer through the spinning nozzle holes 23a, 33a, 43a and 53a is 3 seconds or less, and the flux is at least 0.01 cc/min. In the case of the polyester-based polymers, the retention time exceeding 3 seconds may cause a deterioration of the melted polymer in terms of workability and further a deterioration of the fiber F due to the exposure to an excessive heat; and the flux less than 0.01 cc/min leads to an insufficient heat transfer to the fiber F, making it difficult to control the molecular entanglement structure in the melted polymer and undesirably reducing the effect of improving the properties.
In the spinning nozzle devices of the first to fourth embodiments, the shear rate on the wall surface of the spinning nozzle holes 23a, 33a, 43a, and 53a of the spinning nozzles 23, 33, 43, and 53 is preferably 500 to 500,000/sec. A low shear rate less than 500/sec reduces the effect of controlling the molecular orientation and structure of the melted polymer; and a high shear rate greater than 500,000/sec causes the defective appearance of the film (e.g., melt fracture) due to the viscoelasticity of the melted polymer and eventually an uneven cross-section of the fiber.
The spinning nozzle devices of the first to fourth embodiments are applicable to the melt spinning process using at least one thermoplastic polymer as a raw material. More specifically, the spinning nozzle devices may be applied to a single or composite monofilament spinning process to produce monofilaments having a diameter of 0.01 to 3 mm at a spinning rate of 0.1 to 200 m/min.
The spinning nozzle devices of the first to fourth embodiments are also applicable to a single or composite long fiber spinning process for fibers F of 100 d/f or less (long fibers) using a low rate spinning method (UDY, 100 to 2,000 m/min), a medium-and-low rate spinning method (POY, 2,000 to 4,000 m/min) and a high rate spinning method (HOY, 4,000 m/min or above), and a spinning and in-line drawing process (SDY) in the composite melt spinning process.
The spinning nozzle devices are also applicable to a single or composite staple fiber (short fiber) spinning process to produce a fiber having a diameter of 100 d/f or less at a spinning rate of 100 to 3,000 m/min, or a single or composite unwoven fabric (spun-bond and melt blown) spinning process to yield a unwoven fabric having a diameter of 100 d/f or less at a spinning rate of 100 to 6,000 m/min. In addition, the spinning nozzle devices may be applied to the polymer resin molding and extrusion process or the like.
As described above, the spinning nozzle apparatus of the present invention improves the properties of fibers by utilizing the existing design of the spinning nozzle devices commercially available and the existing processes for melt spinning and drawing, thereby reducing the initial investment cost and realizing a large-quantity production of high-performance fibers at a low cost.
Accordingly, the present invention is available in the tire cords, the interior materials for transportation including automobile, trains, aircrafts, ships, etc., civil engineering and construction materials, electronic materials, marine and military applications such as ropes and nets, and other clothing and household applications, including light-weighted sportswear and work clothes, military uniforms, furniture and interior materials, sports equipment, or the like, so it may expand the market for the wider range of applications.
A local heating method using the spinning nozzle apparatus of the first embodiment was performed with the intrinsic viscosity of the PET resin varied as given in Table 1, and low-rate spinning and off-line drawing were performed under the following conditions to prepare high-strength PET fibers.
(1) Spinning Conditions
(2) Off-Line Drawing Conditions
(1)Measurement conditions: Gauge length 20 mm & test speed 20 mm/min
(2) Spinning rate: 1 km/min
(3),
(4)Drawn yarn obtained at maximum draw ratio available for continuous drawing for at least 10 min.
Property analyses concerning strength and elongation were performed to evaluate the fibers of Examples 1 and 2 as prepared from PET resins having an intrinsic viscosity of 0.65 or 1.2 using a nozzle-based local heating process with the spinning nozzle apparatus according to the first embodiment of the present invention and the fibers of Comparative Examples 1 and 2 as prepared in the same manner excepting that the nozzle-based local heating method was not used (instead, using the same temperature of the pack body temperature). As can be seen from Table 1, the undrawn yarn (as-spun yarn) and the drawn yarn prepared in the Examples 1 and 2 were superior in the properties to those prepared in the Comparative Examples 1 and 2 in the same manner as the Examples 1 and 2 excepting that the nozzle-based local heating process was not performed. The analysis results showed that the low and high molecular PET resins were both enhanced in the properties due to the control of the molecular entanglement structure according to the nozzle-based local heating process.
Particularly, for the drawn yarns of the Examples 1 and 2, as compared with the conventional PET fibers of the Comparative Examples 1 and 2, both the high and low molecular PET fibers had a higher maximum draw ratio by 10% or greater and a roughly equivalent elongation, but with the strength increased by 15% or above.
A local heating method using the spinning nozzle apparatus of the second embodiment was performed with the local heating temperature varied as given in Table 2, and low-rate spinning and off-line drawing were performed under the following conditions to prepare high-strength PET fibers.
(1) Spinning Conditions
(2) Off-Line Drawing Conditions
(1)Measurement conditions: Gauge length 20 mm & test speed 20 mm/min
(2) Spinning rate: 1 km/min
(3),
(4)Drawn yarn obtained at maximum draw ratio available for continuous drawing for at least 10 min.
Property analyses concerning strength and elongation were performed to evaluate the fibers of Examples 1 and 2 as prepared from PET resins having an intrinsic viscosity of 1.2 by varying the heating temperature using a nozzle-based local heating process with the spinning nozzle apparatus according to the second embodiment of the present invention and the fiber of Comparative Example 3 as prepared in the same manner excepting that the nozzle-based local heating method was not used (instead, using the same temperature of the pack body temperature). As can be seen from Table 2, the undrawn yarn (as-spun yarn) and the drawn yarn prepared in the Examples 3 and 4 were superior in the properties to the fiber prepared in the Comparative Example 3 in the same manner as the Examples 3 and 4 excepting that the nozzle-based local heating process was not performed. The property values of the fibers increased with an increase in the heating temperature of the local heating process. The analysis results showed that the high molecular PET resin was enhanced in the properties due to the control of the molecular entanglement structure according to the nozzle-based local heating process. Particularly, as the property values increased with an increase in the heating temperature, it is expected that the properties can be more improved by further increasing the heating temperature.
As compared with the conventional PET fiber of the Comparative Example 3, both the drawn PET fibers of the Examples 3 and 4 had a higher maximum draw ratio by 15% or greater and a roughly equivalent elongation, but with the strength increased by 20% or above.
A local heating method using the spinning nozzle apparatus of the third embodiment was performed under the following conditions to prepare a high-strength PET fiber.
(1) Spinning Conditions
(2) Property Analysis Results
Compared to the PET fiber obtained with the heating body 46 OFF and having a strength of 230 MPa and an elongation of 435%, the PET fiber obtained with the heating body 46 ON displayed a strength of 231 MPa and an elongation of 455%; namely, the strength was roughly equivalent, but the elongation was increased by 4.6% to elevate the toughness.
A local heating method using the spinning nozzle apparatus of the fourth embodiment was performed under the following conditions to prepare a high-strength PET fiber.
(1) Spinning Conditions
(2) Property Analysis Results
Compared to the PET fiber obtained with the heating body 56 OFF and having a strength of 210 MPa and an elongation of 485%, the PET fiber obtained with the heating body 56 ON displayed a strength of 211 MPa and an elongation of 520%; namely, the strength was roughly equivalent, but the elongation was increased by 7.2% to elevate the toughness.
A local heating method using the spinning nozzle apparatus of the fourth embodiment was performed in the same manner as described in Example 6, excepting that an in-line drawing process was performed immediately after a low-rate spinning process under the following conditions, to prepare a PET fiber.
(1) Spinning and High-Rate in-Line Drawing Conditions
(2) Property Analysis Results
Compared to the PET fiber obtained with the heating body 56 OFF and having a strength of 1,180 MPa and an elongation of 11.0%, the PET fiber obtained with the heating body 56 ON displayed a strength of 1,175 MPa and an elongation of 13.8%; namely, the strength was roughly equivalent, but the elongation was increased by 25% to elevate the toughness.
As described above, the spinning nozzle apparatus for manufacturing a high-strength fiber according to the present invention is designed to position the spinning nozzle holes of spinning nozzles on the outside of the pack body in the complex melt spinning process and to optimize a heating method for the portion of the spinning nozzle holes, so it can control the molecular entanglement structure in the melted polymer by applying an instantaneous heat treatment at high temperature to enhance the drawability of thermoplastic polymer fibers and hence improve the mechanical properties such as strength and elongation.
The spinning nozzle apparatus for manufacturing a high-strength fiber according to the present invention adopts the existing processes for melt spinning and drawing but makes an effect to reduce the melt viscosity of the resins, lower the cooling rate of the fibers and improve the drawability of the fibers, resulting in reducing the initial investment cost and realizing a large-quantity production of high-performance fibers at a low cost.
By providing high-strength polyester fibers out of thermoplastic polymers, the spinning nozzle apparatus of the present invention is available to the production of tire cords, interior materials for transportation including automobile, trains, aircrafts, ships, etc., civil engineering and construction materials, electronic materials, marine and military applications such as ropes and nets, and other clothing and household applications, including light-weighted sportswear and work clothes, military uniforms, furniture and interior materials, sports equipment, or the like, and hence promising market expansion for the wider range of applications.
Particularly, by providing high-strength PET fibers, the spinning nozzle apparatus of the present invention is applicable to the production of textile applications including PET long and short fibers, unwoven fabrics, etc., and films, sheets, molds, containers, or the like using those textile materials.
Although the exemplary embodiments of the present invention have been described, it is understood that the present invention should not be limited to these exemplary embodiments but various changes and modifications can be made by one ordinary skilled in the art within the spirit and scope of the present invention as hereinafter claimed.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2016-0054007 | May 2016 | KR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/KR2017/004337 | 4/24/2017 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2017/191916 | 11/9/2017 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 3006028 | Calhoun | Oct 1961 | A |
| 5705119 | Takeuchi | Jan 1998 | A |
| Number | Date | Country |
|---|---|---|
| 2003342826 | Dec 2003 | JP |
| 2014534357 | Dec 2014 | JP |
| 100199471 | Jun 1999 | KR |
| 101171820 | Aug 2012 | KR |
| 101632636 | Jun 2016 | KR |
| Entry |
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| JP 2003342826 machine translation (Year: 2003). |
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| Number | Date | Country | |
|---|---|---|---|
| 20210238768 A1 | Aug 2021 | US |
