Method of manufacturing high-strength synthetic fiber utilizing high-temperature multi-sectional drawing

Abstract

A method of manufacturing a high-strength synthetic fiber utilizing high-temperature multi-sectional drawing, two-stage high-temperature multi-sectional drawing, or multi-stage high-temperature multi-sectional drawing. The method comprises the following steps: performing, on a synthetic resin, melt spinning or melt extrusion, cooling, multi-sectional high-temperature drawing, heat setting and a fiber surface treatment, wherein the multi-sectional high-temperature drawing comprises independently adjusting temperatures at a front section and a rear section of an furnace, and the temperature at the rear section is higher than that at the front section. The temperature adjustment is performed on different locations in the furnace and according to a crystallization orientation of a fiber molecular chain, significantly increasing fiber strength. The method is widely applicable to manufacturing of various types of fibers, enhancing application performance of the fibers.

Claims

1. A method for preparing high strength synthetic fibers by high temperature segmented drawing processes, comprising the following steps: melt spinning or melt extrusion of synthetic resins, cooling, high temperature segmented drawing and heat setting; wherein in the high temperature segmented drawing, the temperature of a front part and a latter part of an oven is independently controlled, where the temperature of the latter part is higher than that of the front part, the heating temperature of the front part in the oven is 30 to 200° C., and that of the latter part is 50 to 300° C.

2. The method as claimed in claim 1, wherein the drawing ratio is 1 to 50 times.

3. A method for preparing high strength synthetic fibers by two-stage high temperature segmented drawing processes, comprising the following steps: melt spinning or melt extrusion of synthetic resins, cooling, high temperature segmented drawing and heat setting; wherein the high temperature segmented drawing comprises a first and a second drawing stages in first and second ovens respectively, the temperature of a front part and a latter part of the first oven being independently controlled, where the temperature of the latter part is higher than that of the front part and the heating temperature of the front part of the second drawing stage is not lower than that of the latter part of the first drawing stage, in the first drawing stage, the temperature of the front part in the first oven is 30 to 200° C. and the heating temperature of the latter part is 50 to 300° C.; in the second drawing stage, the heating temperature of the front part in the second oven is 100 to 300° C., and the heating temperature of the latter part is 120 to 300° C.

4. The method as claimed in claim 3, wherein the drawing ratio is 1 to 50 in the first drawing stage, and the drawing ratio is 1 to 80 in the second drawing stage.

5. A method for preparing high strength synthetic fibers by multi-stage high temperature segmented drawing processes, comprising the following steps: melt spinning or melt extrusion of synthetic resins, cooling, high temperature segmented drawing and heat setting; wherein the high temperature segmented drawing comprises multiple stages, the high temperature segmented drawing process comprises sequentially entering multiple ovens, and the heating temperature and drawing ratio of the front part of a latter oven in the multiple ovens is not lower than that of a front oven in the multiple ovens, wherein in the high temperature segmented drawing, the temperature of a front part and a latter part of one of the ovens is independently controlled and the temperature of the latter part is higher than that of the front part, at least three stages of high temperature drawing are included, and the first three stages of high temperature drawing are as follows: the heating temperature of the front part in the first drawing stage is 30 to 200° C., and the heating temperature in the latter part is 50 to 200; the heating temperature of front part in the second drawing stage is 100 to 250° C., and the heating temperature of the latter stage is 120 to 250° C.; the heating temperature of front part in the third drawing stage is 100 to 300° C., and the heating temperature of the latter part is 120 to 300° C.

6. The method as claimed in claim 5, wherein the multi-stage high temperature segmented drawing process comprises three stages.

7. The method as claimed in claim 5, wherein the drawing ratio of the first stage is 1 to 50, the drawing ratio of the second stage is 1 to 80, and the drawing ratio of the third stage is 1 to 100.

8. The method as claimed in claim 5, wherein there are more than three stages in multi-stage high temperature segmented drawing, and the temperature and the drawing ratio after the third stage are the same as those of the third stage.

9. The method as claimed in claim 1, wherein the length ratio of the front heating part to the latter heating part in the oven is 1:5 to 5:1.

10. The method as claimed in claim 9, wherein the length ratio of the front heating part to the latter heating part in the oven is 1:3 to 3:1.

11. The method as claimed in claim 1, wherein the synthetic resins are one of or a mixture of more than one of the following chemicals: polypropylene, polyethylene, polyacrylonitrile fiber, polyester, polyamide, polyvinyl alcohol, polyvinyl formal, polyethylene terephthalate, polybenzimidazole, polytetrafluoroethylene, Poly(p-phenylene terephthalamide) and polyimide.

12. The method as claimed in claim 1, wherein the synthetic resins include modifiers, modified resins or modified fillers.

13. The method as claimed in claim 12, wherein the modifiers, modified resins or modified fillers are one of or a mixture of following chemicals: silane coupling agent Si-69, silane coupling agent KH570, silane coupling agent KH550, silane coupling agent KH151, silica gel anti-blocking agent, titanate coupling agent, aluminate coupling agent, tetraethyl orthosilicate (TEOS), color masterbatch, plasticizing masterbatch, high-temperature-resistant masterbatch, anti-corrosion masterbatch, defoaming masterbatch, inorganic ultrafine particles, maleic anhydride grafted polypropylene, maleic anhydride grafted polyethylene, polyethylene glycol, polybutylene adipate, and polycaprolactone.

14. The method as claimed in claim 1, wherein fiber surface treatment is performed after heat setting.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1 is a schematic diagram of the device of Embodiment 1 to 3 of the present invention.

(2) FIG. 2 is a schematic diagram of the device of Embodiment 4 to 6 of the present invention.

(3) FIG. 3 is a schematic diagram of the device of Embodiment 7 to 9 of the present invention.

DETAILED DESCRIPTION

(4) The present invention will be further explained below with reference to the figures attached by way of examples.

Embodiment 1

(5) This embodiment is applied to the preparation of high strength polypropylene fibers. The preparation process is shown in FIG. 1 and includes the following steps:

(6) Polypropylene resin, maleic anhydride grafted polypropylene, color master batch, high temperature resistant master batch, anti-corrosion master batch and defoaming master batch are fully and evenly mixed and then added into a single screw extruder for melt extrusion. After the fibers are extruded, they are immediately cooled in cooling water to obtain undrawn filaments in an amorphous state. The fibers are subjected to high temperature segmented drawing. The total length of the heating oven is 6 m. The length of the front heating part is 2 m and the temperature is 140° C. while the length of the latter heating part is 4 m and the temperature is 150° C. Two ends of the oven are respectively provided with a roller, the rotating speed of the first roller is 5 m/min, the rotating speed of the second roller is 50 m/min, and the drawing ratio is 10. The drafted fibers are heat set at a high temperature of 120° C. and the rotating speed of the roller of the heat set oven is the same as that of the roller at the rear end of the oven, which is also 50 m/min. The setting time is 40 s. After that, fibers are indented, modified, packaged and cut to obtain the finished product. The tensile strength of the polypropylene fibers in this example reaches 450 MPa and the tensile modulus reaches 7 GPa, which was 25% higher than that of the polypropylene fibers prepared by the conventional method.

Embodiment 2

(7) This embodiment is applied to the preparation of high strength polyester amide fibers. The preparation process is shown in FIG. 1 and includes the following steps:

(8) Nylon 6 and polybutylene adipate are copolymerized and then added into a single screw extruder for melt extrusion. After the fibers are extruded, they are immediately cooled in cooling water to obtain undrawn filaments in an amorphous state. The fibers are subjected to high temperature segmented drawing. The total length of the heating oven is 6 m. The length of the front heating part is 3 m and the temperature is 70° C. The length of the latter heating part is 3 m, the temperature is 80° C. The drawing ratio is 10. The control method of the drawing speed rate is the same as in Embodiment 1. The drafted fibers are heat set, packaged and cut to obtain the finished product. The tensile strength of the polyester amide fiber of this example reaches 800 MPa and the tensile modulus reaches 6 GPa, which is 30% higher than that of the polyester amide fiber prepared by the conventional method.

Embodiment 3

(9) This embodiment is applied to the preparation of high strength polyvinyl alcohol fibers. The preparation process is shown in FIG. 1 and includes the following steps:

(10) After swelling, polyvinyl alcohols are added into a single screw extruder for melt extrusion. After the fibers are extruded, freezing, alcoholysis and neutralization are carried out. The fibers are subjected to high temperature segmented drawing. The total length of the heating oven is 6 m. The length of the front heating part is 4 m and the temperature is 140° C. The length of the latter heating part is 2 m and the temperature is 150° C. The drawing ratio is 8. The control method of the drawing speed rate is the same as in Embodiment 1. The drawn fibers are heat set, packaged and cut at 220° C. to obtain the finished product. The tensile strength of the polyvinyl alcohol fiber in this embodiment reaches 700 MPa and the tensile modulus reaches 25 GPa, which is 15% higher than that of the polyvinyl alcohol fiber prepared by the conventional method.

Embodiment 4

(11) This embodiment is applied to the preparation of high strength polypropylene fibers. The preparation process is shown in FIG. 2 and includes the following steps:

(12) Polypropylene resin, maleic anhydride grafted polypropylene, color master batch, high temperature resistant master batch, anti-corrosion master batch and defoaming master batch are fully and evenly mixed and then added into a single screw extruder for melt extrusion. After the fibers are extruded, they are immediately cooled in cooling water to obtain undrawn filaments in an amorphous state. The fiber is subjected to two-stage high temperature segmented drawing. In the first stage, the total length of the heating oven is 6 m. The length of the front heating part is 2 m and the temperature is 50° C. The length of the latter heating part is 4 m and the temperature is 60° C. Both ends of the first oven are respectively provided with a roller. The rotating speed of the first roller is 3 m/min, and the rotating speed of the second roller is 15 m/min. The drawing ratio is 5. In the second stage, the total length of the heating oven is 6 m. The length of the front heating part is 2 m and the temperature is 150° C. The length of the latter heating part is 4 m, and the temperature is 160° C. The roller at the rear end of the first oven and the roller at the front end of the second oven is the same one. The rotating speed of the roller at the rear end of the second oven is 150 m/min, and the drawing ratio is 10. The drafted fibers are subjected to high temperature heat setting. The rotating speed of the roller of the heat setting oven is the same with that of the roller at the rear end of the second oven, the heat setting temperature is 120° C., and the setting time is 40 s. After that, the fibers are indented, modified, packaged and cut to obtain the finished product. The tensile strength of the polypropylene fiber in this embodiment reaches 550 MPa and the tensile modulus reaches 9 GPa.

Embodiment 5

(13) This embodiment is applied to the preparation of high strength polyester amide fibers. The preparation process is shown in FIG. 2 and includes the following steps:

(14) Nylon 6 and polybutylene adipate are copolymerized and then added into a single screw extruder for melt extrusion. After the fibers are extruded, they are immediately cooled in cooling water to obtain undrawn filaments in an amorphous state. The fibers are subjected to two-stage high temperature segmented drawing. In the first stage, the total length of the heating oven is 6 m. The length of the front heating part is 3 m and the temperature is 20° C. The length of the latter heating part is 3 m and the temperature is 30° C. The drawing ratio is 2. In the second stage, the total length of the heating oven is 6 m. The length of the front heating part is 3 m and the temperature is 70° C. The length of the latter heating part is 3 m and the temperature is 80° C. The drawing ratio is 5. The control method of the drawing speed rate is the same as in Embodiment 4. The drawn fibers are heat set, packaged and cut to obtain the finished product. The tensile strength of the polyester amide fiber in this embodiment reaches 1000 MPa and the tensile modulus reaches 8 GPa.

Embodiment 6

(15) This embodiment is applied to the preparation of high strength polyvinyl alcohol fibers.

(16) The preparation process is shown in FIG. 2 and includes the following steps:

(17) After swelling, polyvinyl alcohol is added into a single screw extruder for melt extrusion. After the fibers are extruded, freezing, alcoholysis and neutralization are carried out. The fibers are subjected to two-stage high temperature segmented drawing. In the first stage, the total length of the heating oven is 6 m. The length of the front heating part is 4 m and the temperature is 90° C. The length of the latter heating part is 2 m and the temperature is 100° C. The drawing ratio is 3. In the second stage, the total length of the heating oven is 6 m. The front heating part length is 4 m and temperature is 140° C. The length of the latter heating part length is 2 m and temperature is 150° C. The drawing ratio is 6. The control method of the drawing speed rate is the same as in Embodiment 4. The drawn fiber is heat set, packaged and cut at 220° C. to obtain the finished product. The tensile strength of the polyvinyl alcohol fiber in this embodiment reaches 950 MPa and the tensile modulus reaches 35 GPa.

Embodiment 7

(18) This embodiment is applied to the preparation of high strength polypropylene fibers. The preparation process is shown in FIG. 3 and includes the following steps:

(19) Polypropylene resin, maleic anhydride grafted polypropylene, color master batch, high temperature resistant master batch, anti-corrosion master batch and defoaming master batch are fully and evenly mixed and then added into a single screw extruder for melt extrusion. After the fibers are extruded, they are immediately cooled in cooling water to obtain undrawn filaments in an amorphous state. The fibers are subjected to three-stage high temperature segmented drawing. In the first stage, the total length of the heating oven is 6 m. The length of the front heating part is 2 m and the temperature is 40° C. The length of the latter heating part is 4 m and the temperature is 50° C. Both ends of the first oven are respectively provided with a roller. The rotating speed of the first roller is 3 m/min, the rotating speed of the second roller is 6 m/min, and the drawing ratio is 2. In the second stage, the total length of the heating oven is 6 m. The length of the front heating part is 2 m and the temperature is 120° C. The length of the latter heating part is 4 m and the temperature is 140° C. The roller at the rear end of the first oven and the roller at the front end of the second oven is the same one. The rotating speed of the roller at the rear end of the second oven is 24 m/min, and the drawing ratio is 4. In the third stage, the total length of the heating oven is 6 m. The length of the front heating part is 2 m and the temperature is 150° C. The length of the rear heating part is 4 m and the temperature is 160° C. The roller at the rear end of the second oven and the roller at the front end of the third oven is the same one. The rotating speed of the roller at the rear end of the third oven is 144 m/min, and the drawing ratio is 6. The drafted fiber is heat set at 120° C. for 40 s. After that, the fibers are indented, modified, packaged and cut to obtain the finished product. The tensile strength of the polypropylene fiber in this embodiment reaches 700 MPa and the tensile modulus reaches 15 GPa. It is also possible to further add the fourth or even fifth stage high temperature segmented drawing according to needs, under the same conditions as the third stage.

Embodiment 8

(20) This embodiment is applied to the preparation of high strength polyester amide fibers. The preparation process is shown in FIG. 3 and includes the following steps:

(21) Nylon 6 and polybutylene adipate are copolymerized and then added into a single screw extruder for melt extrusion. After the fibers are extruded, they are immediately cooled in cooling water to obtain undrawn filaments in an amorphous state. The fibers are subjected to three-stage high temperature segmented drawing. In the first stage, the total length of the heating oven is 6 m. The length of the front heating part is 3 m and the temperature is 20° C. The length of the latter heating part is 3 m and the temperature is 30° C. The drawing ratio is 1. In the second stage, the total length of the heating oven is 6 m. The length of the front heating part is 3 m and the temperature is 40° C. The length of the latter heating part is 3 m and the temperature is 60° C. The drawing ratio is 3. In the third stage, the total length of the heating oven is 6 m. The length of the front heating part is 3 m and the temperature is 70° C. The length of the rear heating part is 3 m and the temperature is 80° C. The drawing ratio is 5. The rate control method is the same as in Embodiment 7. The drafted fibers are heat set, packaged and cut to obtain the finished product. The tensile strength of the polyester amide fiber in this embodiment reaches 1500 MPa and the Tensile modulus reaches 10 GPa.

Embodiment 9

(22) This embodiment is applied to the preparation of high to strength polyvinyl alcohol fibers. the preparation process is shown in FIG. 3 and includes the following steps:

(23) After swelling, polyvinyl alcohol is added into a single screw extruder for melt extrusion. After the fibers are extruded, freezing, alcoholysis and neutralization are carried out. The fiber are subjected to three stages of high temperature segmented drawing. In the first stage, the total length of the heating oven is 6 m. The length of the front heating part is 4 m and the temperature is 90° C. The length of the rear heating part is 2 m and the temperature is 100° C. And the drawing ratio is 2. In the second drawing stage, the total length of the heating oven is 6 m. The length of the front heating part is 4 m and the temperature is 140° C. The length of the rear heating part is 2 m and the temperature is 150° C. The drawing ratio is 3. In the third drawing stage, the total length of the heating oven is 6 m. The length of the front heating part is 4 m and the temperature is 190° C. The length of the rear heating part is 2 m and the temperature is 200° C. The drawing ratio is 5. The rate control method is the same as in Embodiment 7. The drawn fibers are heat set, packaged and cut at 220° C. to obtain the finished product. The tensile strength of the polyvinyl alcohol fiber in this embodiment reaches 1200 MPa and the tensile modulus reaches 40 GPa.

(24) The above described are only some preferred embodiments of the present invention, but the scope of protection of the present invention is not limited to the above embodiments. Any changes or substitutions, such as specific temperature adjustment of front and rear, which can be easily thought of by those skilled in this art, do not depart from the scope of protection of this present invention. Therefore, the scope of protection of the present invention should be based on that of the claims.