Basf Corporation

Charles F Helms, Jr

Matthew B Hoyt

Diane R Kent

Otto M Ilg

John A Hodan

Dominick A Burlone

Karl H Buchanan

Stanley A McIntosh

Frank R Jones

Wayne S Stanko

G Daniel Gasperson

David B Ledford

Gary W Shore

Thomas Kessler

Richard Kotek

J&uuml;rgen Hofmann

Randall A Sferrazza

Carol W Morgan

Walter Gotz

Herman Brandt

James L Huff

Terry D Roberts

Fang A Wang

Ronald G Morrow

Phillip E Wilson

Donald Caswell

James R Bristow

Gary A Shore

Jeffrey S Dugan

Wendel L Burton

Michael A Davis

Keith V Blankenship

Harold R Vickery

Continuous anionic polymerization and melt-spinning of a polycaprolactam includes forming a reaction mixture by bringing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator into contact with one another, and then subjecting the reaction mixture to anionic polymerization reaction conditions in the reactor zone to obtain a molten polycaprolactam. The molten polycaprolactam is the directly (i.e., without intermediate solidification) transferred to, and extruded through, a fiber-forming orifice of a spinneret to form a fiber thereof. A spinneret zone downstream of the reactor zone thus receives the molten polycaprolactam directly from the reactor zone and forms a fiber therefrom by extruding it through the spinneret's fiber-spinning orifice.

Continuous polymerization and direct fiber spinning and systems for accomplishing same

Continuous anionic polymerization and melt-spinning of a polycaprolactam includes forming a reaction mixture by bringing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator into contact with one another, and then subjecting the reaction mixture to anionic polymerization reaction conditions to obtain a molten polycaprolactam. The molten polycaprolactam is the directly (i.e., without intermediate solidification) transferred to, and extruded through, a fiber-forming orifice of a spinneret to form a fiber thereof. One exemplary system to achieve such continuous anionic polymerization and melt-spinning of polycaprolactam includes a mixer for receiving and mixing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator, and a reactor and melt-spinning apparatus downstream of the mixer. The reactor and melt-spinning apparatus most preferably is formed of multiple plates which establish a reactor zone having a flow path for the reaction mixture which is sized and configured to achieve a predetermined residence time of the reaction mixture therein, and a temperature control zone in thermal communication with the reactor plate for controlling the temperature of the reaction plate to achieve anionic polymerization reaction conditions while the reaction mixture is flowing along the defined flow path therein to obtain the molten polycaprolactam. A spinneret zone downstream of the reactor zone thus receives the molten polycaprolactam directly and forms a fiber therefrom by extruding it through the spinneret's fiber-spinning orifice.

This invention provides an apparatus and method for injecting an additive directly into a polymer melt stream. The method comprises supplying a melt flow of a polymeric host material to a die assembly having a thin-plate assembly and injecting at least one additive into at least one predetermined location in a cross-section of the melt flow of the polymeric host material while the melt flow passes through the die assembly. The method achieves uniform dosing of the one or more additives in the extrusion direction in the polymeric host material without homogeneously mixing the one or more additives and the polymeric host material. The apparatus for directly injecting one or more additives into a polymer melt stream comprises a pumping system, a die assembly having a thin-plate assembly, and a distribution line.

Apparatus and method for direct injection of additives into a polymer melt stream

Continuous polymerization and direct fiber spinning and apparatus for accomplishing same

Polymeric compositions include a nonaqueous additive system having dispersant-coated pigments physically dispersed in a liquid nonaqueous polymeric carrier which may be added directly to a melt flow of a polymeric host material. The additive system employed in the polymeric systems is most preferably in the form of a particulate paste which can be added in metered amounts (dosed) to a melt flow of the polymeric host material prior to being spun into filaments. By providing a number of additive systems having a number of different additive attributes, and controllably dosing one or more into the melt flow of host polymeric material, shaped objects of the polymeric material (e.g., melt-spun filaments) having different additive attributes may be produced on a continuous basis without shutting down the shaping operation.

Methods of making pigmented filaments

Spinnerette assemblies for forming synthetic fibers whereby a relatively thin orifice plate is compressively sealed against a planar face of a mounting block. The spinnerette assemblies preferably include a mounting block having a planar mounting face and a least one supply bore having a discharge opening at the mounting face. A planar orifice plate is positioned in contact with the mounting face of the mounting block and includes a capillary opening in fluid communication with the discharge opening of the supply bore. A series of attachments (preferably screws) circumferentially surround the capillary opening of the orifice plate so as to compressively rigidly fix the orifice plate to the mounting face of the mounting block and thereby seal the capillary opening against fluid leakage. Most preferably, the attachments (e.g., screws) are substantially equally circumferentially spaced apart from one another in surrounding relationship to the capillary opening so as to impart a symmetrical circumferential compressive sealing force therearound.

Thin plate spinnerette assembly

Methods of making multiphase elongate polymeric extrudates by directing additives into a cross-sectional location thereof

At least two different liquid streams are sub-divided into a dense plurality of individually separated parallel pixels oriented in respective misregistered arrays. Therefore, an individual pixel of one of the liquid stream arrays will be surrounded by pixels of the other liquid stream array. These individual pixel arrays are then bought into contact with one another to form a multi-pixel liquid stream comprised of the misregistered pixel arrays of the two different liquid streams. The &ldquo;pixelated&rdquo; liquid stream&mdash;that is, the liquid stream containing in cross-section the misregistered pixel arrays of the two different liquid streams&mdash;may then be further processed. For example, the pixelated liquid stream may be subjected to further mixing by being directed along a tortuous flow path.

Multi-pixel liquid streams, especially fiber-forming polymeric streams, and methods and apparatus for forming same

Dispersible additive systems for polymeric materials, and methods of making and incorporating the same in such polymeric materials

Relatively thin (e.g., thickness of less than about 2.5 mm, and typically no greater than about 1.0 mm) plates for synthetic fiber-forming spin packs include a first metal layer exhibiting a relatively slow photochemical etching property and a second metal layer exhibiting a relatively fast photochemical etching property which are adhered (laminated) to one another to form a composite substrate structure. The differential etch rates as between the first and second metal layers permit relatively dimensionally larger distribution channels and relatively dimensionally precise through holes to be formed in the composite substrate. In this regard, the second metal layer permits the formation via photochemical etching of dimensionally deeper and/or wider polymer distribution channels. The first metal layer, on the other hand, allows for the formation of relatively dimensionally precise through holes via concurrent (simultaneous) etching with the second metal layer.

Photochemically etched plates for synthetic fiber-forming spin packs and method of making same

Multicomponent fibers and methods of producing the same are provided such that an inter-domain boundary layer is interposed between distinct domains formed of incompatible polymers so as to minimize (if not eliminate entirely) separation of the domains at their interfacial boundary. The polymer forming the inter-domain boundary layer therefore is provided so as to be compatible with the otherwise incompatible polymers forming each of the domains between which it is interposed.

Process of making multicomponent fiber

Bicomponent fibers of different cross-sections may be formed without changing the geometry of the spinneret orifices. More specifically, at least two polymers are co-melt-spun through an orifice of fixed geometry so as to achieve a bicomponent fiber having a desired cross-section. In order to change to a bicomponent fiber having a cross-section which is different, therefore, at least one of (1) the differential relative viscosity, (2) the relative proportions of the first and/or second polymers, and (3) the cross-sectional bicomponent distribution of the first and second polymers, is changed. In such a manner, therefore, a wide variety of bicomponent fibers having different cross-sectional geometries may be produced without changing the fixed geometry orifice through which the polymers are co-melt-spun. Thus, bicomponent fiber cross-sections may be 'engineered' to suit a variety of needs without necessarily shutting down production equipment in order to change spinnerets. The bicomponent fibers are most preferably multilobal (e.g., trilobal) in which the core component is generally triangularly shaped.

Process for modifying synthetic bicomponent fiber cross-sections

Novel bicomponent fibers have a sheath domain and an core domain which is embedded entirely within, and thereby completely surrounded by, the polyamide domain. The core domain is annular and defines a longitudinally extending central void. The preferred bicomponent fibers have a sheath-core structure wherein the polyamide domain constitutes the sheath and a fiber-forming polyolefin polymer constitutes the core. The preferred trilobal bicomponent fibers will exhibit a modification ratio of between 2 to 4, an arm angle of between 7.degree. to about 35.degree., and a total cross-sectional void area between about 3 and about 10 percent. Each lobe of the fiber may optionally contain a lobal void space which, if present, is preferably radially elongate in cross-section.

Method of making hollow bicomponent filaments

Multicomponent fibers and methods and apparatus for producing the same are provided such that an inter-domain boundary layer is interposed between distinct domains formed of incompatible polymers so as to minimize (if not eliminate entirely) separation of the domains at their interfacial boundary. The inter-domain boundary layer is formed of a heterogeneous mixture of the polymers forming the respective adjacent domains between which the boundary layer is interposed. The inter-boundary layer will most preferably include rivulets or fingers of each polymer forming the adjacent domains which interlock with one another in a randomly tortuous manner. These different polymer rivulets thereby effectively increase the surface area and mechanical interlocking at the interfacial boundary between the fiber domains thereby increasing the adhesion therebetween.

Process of making a multiple domain fiber having an inter-domain

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Asheville, NC, United States of America

Charles F Helms, Jr