Basf Corporation

Other

John A Hodan

Otto M Ilg

Matthew B Hoyt

Charles F Helms, Jr

Dominick A Burlone

Richard Kotek

Randall A Sferrazza

Carol W Morgan

Fang A Wang

Ronald G Morrow

Terry D Roberts

Diane R Kent

Robert N Armstrong

Wei Ping Li

Jeffrey S Dugan

Gary W Shore

Donald Barry Thompson

Karl H Buchanan

Wendel L Burton

Melvin R Thompson

James R Lisk, Jr

Robert E First

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.

Continuous polymerization and direct fiber spinning and apparatus for accomplishing same

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

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

A thermoplastic fiber demonstrates moisture wicking properties. The fiber has one or more internal lenghtwise open channels each having an opening and at least one groove having a deepest point, a longest dimension and a mouth. The mouth is defined by moving a line from the deepest point along the longest dimension until the largest convex set is identified. The mouth is at the line segment closing the largest convex set. The mouth has width x wherein the average transverse cross-sectional area of the groove is greater than or equal to (.pi.x.sup.2)/8. A durable hydrophilic surface modification is assosiated with said channel.

Moisture transport fiber

Process for modifying synthetic bicomponent fiber cross-sections and

Electrically conductive fiber is made from a multicomponent filament having a suffusible component present at some or all of the periphery of the filament, and an impervious component that is substantially impervious to a suffusion coating solution. Finely-divided, electrically conductive particles suffuse into a surface of the suffusible component to render an electrical resistance in the filament of not more than about 10.sup.9 ohms/cm but do not significantly suffuse into the impervious component. The multicomponent fiber has finely-divided, electrically conductive particles suffused into the suffusible component but not significantly into the impervious component.

Multicomponent suffused antistatic fibers and processes for making them

Electrically conductive fiber is made from a multicomponent filament having a suffusible component present at some or all of the periphery of the filament, and an impervious component that is substantially impervious to a suffusion coating solution. Finely-divided, electrically conductive particles are suffused into a surface of the suffusible component to render an electrical resistance in the filament of not more than about 10.sup.9 ohms/cm but the particles do not significantly suffuse into the impervious component.

Process for making multicomponent antistatic fibers

A system for mixing first and second polymer melt flows and directing a mixed polymer melt flow to one and another downstream locations includes a control valve having an inlet port for receiving the first polymer melt flow, and a pair of outlet ports, and a fluidic valve for forming the mixed flow of the first and second polymer melt flows and directing the mixed flow to one of a plurality of downstream locations. The fluidic valve is provided with a primary supply port for receiving the second polymer melt flow, a pair of secondary supply ports which are fluid-connected with the primary supply port at a mixing intersection, and a plurality of discharge ports extending from the mixing intersection. Each discharge port directs the mixed flow of the first and second polymer melt flows to a respective downstream location. A pair of branch conduits is provided which fluid-connect one of the pair of outlet ports of the control valve to a respective one of the secondary supply ports of the fluidic valve.

Apparatus for melt mixing synthetic polymers

An apparatus for melt mixing and spinning synthetic polymers, which has a plurality of spinning nozzle units, a main extruder with a capacity sufficient to feed a polymer melt to the plurality of spinning nozzle units, a main metering pump for receiving the polymer melt through a conduit system from the main extruder and directing the polymer melt through a branched conduit system including a first branch and a second branch to the spinning nozzle unit, a plurality of multiple way fluidic devices, a two way valve for receiving the polymer melt from the main metering pump and for directing the polymer melt through the first branch or through the second branch and through the multiple way fluidic devices to the plurality of spinning nozzle units, thereby directing the way within the multiple way fluidic devices, a plurality of concentrate extruders for directing a plurality of concentrates through the multiple way fluidic devices to the spinning nozzle units, each of said multiple way fluidic devices thereby combining the polymer melt received from the first branch with one of the concentrates to a polymer melt mixture and directing the polymer melt mixture to one of the plurality of spinning nozzles units.

Apparatus for melt mixing and spinning synthetic polymers

Synthetic polymers are melt-mixed and spun from a mixture of respective first and second polymer melt flows. Specifically, the mixture of first and second polymer melt flows are mixed at a fluidic mixing device having a mixing intersection which receives the first and second polymer melt flows and discharges the mixture thereof respectively into at least one or another of multiple discharge ports fluid-connected with a respective spinning nozzle. The mixed flow of first and second polymer melt flows is controlled by diverting the first polymer melt so that it (i) entirely flows along a first flow path to responsively merge with the second polymer melt flow at the mixing intersection of the mixing device and thereby cause the mixed polymer flow to be discharged through the one discharge port, or (ii) entirely flow along a second flow path to responsively merge with the second polymer melt at the mixing intersection of the mixing device and thereby cause the mixed polymer flow to be discharged through the other discharge port. The mixed polymer flow thereby diverted is thus spun by one or another of the spinning nozzles, respectively.

Process for melt mixing and spinning synthetic polymer

A spin pack for spinning synthetic fibers from two or more liquid polymer streams includes a supply for at least two polymer streams to the spin pack; a spinneret having extrusion orifices; and flow distribution plate sets. The flow distribution plate sets include at least one patterned plate having edges which define a substantially regular two-dimensional geometric shape, a substantially planar upstream surface, a substantially planar downstream surface and at least one flow distribution pattern stenciled therein by cutting through. For each patterned plate, at least one boundary plate stacked sealingly adjacent thereto and having edges which define a substantially regular geometric shape, a substantially planar upstream surface and a substantially planar downstream surface. The boundary plate has cut-through holes connecting the upstream surface with the downstream surface to form at least one flow-through channel to allow fluid flow through the patterned plate but otherwise is substantially solid.

Melt-spinning synthetic polymeric fibers

A spin pack for spinning synthetic fibers from two or more liquid polymer streams includes a supply for at least two discrete polymer streams without mixing with another discrete stream to the spin pack; a spinneret having extrusion orifices; and flow distribution plate sets. The flow distribution plate sets include at least one patterned plate having edges which define a substantially regular two-dimensional geometric shape, a substantially planar upstream surface, a substantially planar downstream surface and at least one flow distribution pattern stenciled therein by cutting through. For each patterned plate, at least one boundary plate stacked sealingly adjacent thereto and having edges which define a substantially regular geometric shape, a substantially planar upstream surface and a substantially planar downstream surface. The boundary plate has cut-through holes connecting the upstream surface with the downstream surface to form at least one flow-through channel to allow fluid flow through the patterned plate but otherwise is substantially solid.

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Arden, NC, United States of America

John A Hodan