Dispersible fiber bundles and suspensions using environmentally-friendly solvents

Abstract

Methods of preparing dispersible fiber bundles comprising contacting a rheology-modifying binder to at least two or more fibers to form a binder-fiber mixture, and imparting force to the binder-fiber mixture to compact the binder-fiber mixture into a fiber bundle.

What is claimed is: 
     
         1 . A method of preparing dispersible fiber bundles comprising contacting a rheology-modifying binder with at least two or more fibers to form a binder-fiber mixture, and imparting force to the binder-fiber mixture to compact the binder-fiber mixture into a fiber bundle, wherein the rheology-modifying binder is selected from at least one guar, at least one derivatized guar, at least one modified cellulose, at least one acrylate, at least one viscoelastic surfactant, or any combination thereof. 
     
     
         2 . The method of  claim 1  wherein the rheology-modifying binder is at selected from at least one guar, 
     
     
         3 . A method of preparing dispersible fiber bundles comprising:
 contacting a rheology-modifying binder with at least two or more fibers to form a binder-fiber mixture;   imparting force to the binder-fiber mixture to substantially orient the at least two fibers in a first direction, thereby forming a fiber bundle; and   severing the fiber bundle into two or more shorter length fiber bundles.   
     
     
         4 . The method of  claim 3  wherein the rheology-modifying binder is selected from at least one guar, at least one derivatized guar, at least one modified cellulose, at least one acrylate, at least one viscoelastic surfactant, or any combination thereof. 
     
     
         5 . The method of  claim 3  wherein the at least two fibers are oriented in a substantially longitudinal direction. 
     
     
         6 . The method of  claim 3  wherein the at least two fibers are selected from cellulose acetate, polyamide, PLA, PGA, PEEK, acrylic, polyester, glass, metal, inorganic, poly-3-hydroxybutyrate (PHB), polyhydroxyalkanoates (PHA), Polyamide 11 (PA 11) or any combination thereof. 
     
     
         7 . A method of preparing a dispersible fiber bundle slurry comprising:
 contacting a rheology-modifying binder to at least two or more fibers to form a binder-fiber mixture,   imparting force to the binder-fiber mixture to substantially orient the at least two fibers in a first direction, thereby forming a fiber bundle; and   contacting the fiber bundle with a solvent blend, the solvent blend comprising at least one of the following components:
 a) dialkyl methylglutarate; 
 b) a first blend of: dialkyl methylglutarate, dialkyl ethylsuccinate and, optionally, dialkyl adipate; 
 c) a second blend of: dialkyl adipate, dialkyl glutarate and dialkyl succinate; 
 d) a dioxolane compound of formula I: 
   
       
         
           
           
               
               
           
         
       
       wherein R6 and R7, which may be identical or different, is individually a hydrogen, an alkyl group, an alkenyl group, or a phenyl group, wherein n is an integer of from 1 to 10; and
   e) a compound or mixture of compounds having formula (II):
   R 3 OOC-A-CONR 4 R 5   (II),
 
   
 
       wherein R 3  is a group chosen from saturated or unsaturated, linear or branched, optionally cyclic, optionally aromatic hydrocarbon-based groups comprising an average number of carbon atoms ranging from 1 to 36; wherein R 4  and R 5 , which are identical or different, are groups chosen from saturated or unsaturated, linear or branched, optionally cyclic, optionally aromatic, optionally substituted hydrocarbon-based groups comprising an average number of carbon atoms ranging from 1 to 36, it being possible for R 4  and R 5  to optionally together form a ring, that is optionally substituted; and wherein A is a linear or branched divalent alkyl group comprising an average number of carbon atoms ranging from 2 to 12. 
     
     
         8 . The method of  claim 7  wherein the at least two fibers are oriented in a substantially longitudinal direction. 
     
     
         9 . The method of  claim 7  further comprising:
 severing the fiber bundle into two or more shorter length fiber bundles; or 
 compacting the fiber bundle. 
 
     
     
         10 . The method of  claim 7  wherein the at least two fibers are selected from cellulose acetate, polyamide, PLA, PGA, PEEK, acrylic, polyester, glass, metal, inorganic, poly-3-hydroxybutyrate (PHB), polyhydroxyalkanoates (PHA), Polyamide 11 (PA 11) or any combination thereof. 
     
     
         11 . A fiber bundle comprising:
 at least two polymer fibers; and   a rheology-modifying binder comprising at least, one guar, at least one derivatized guar, at least one modified cellulose, at least one cellulose, at least one acrylate, at least one viscoelastic surfactant, or any combination thereof, wherein the fibers are treated with an effective amount of the binder to enhance the cohesion of the fiber bundle.   
     
     
         12 . The fiber bundle of  claim 11  wherein the at least two polymer fibers is selected from cellulose acetate, polyamide, PLA, PGA, PEEK, acrylic, polyester, glass, metal, inorganic, poly-3-hydroxybutyrate (PHB), polyhydroxyalkanoates (PHA), Polyamide 11 (PA 11) or any combination thereof. 
     
     
         13 . A fiber bundle slurry comprising:
 a fiber bundle comprising:
 a) at least two polymer fibers; and 
 b) a rheology-modifying binder comprising at least one guar, at least one derivatized guar, at least one modified cellulose, at least one cellulose, at least one acrylate, at least one viscoelastic surfactant, or any combination thereof, wherein the fibers are treated with an effective amount of the binder to enhance the cohesion of the fiber bundle; 
 a solvent blend comprising at least one of the following components: 
   a) dialkyl methylglutarate;   b) a first blend of: dialkyl methylglutarate, dialkyl ethylsuccinate and, optionally, dialkyl adipate;   c) a second blend of: dialkyl adipate, dialkyl glutarate and dialkyl succinate;   d) a dioxolane compound of formula I:   
       
         
           
           
               
               
           
         
       
       wherein R6 and R7, which may be identical or different, is individually a hydrogen, an alkyl group, an alkenyl group, or a phenyl group, wherein n is an integer of from 1 to 10; and
 e) a compound or mixture of compounds having formula (II):
   R 3 OOC-A-CONR 4 R 5   (II),
 
 
 
       wherein R 3  is a group chosen from saturated or unsaturated, linear or branched, optionally cyclic, optionally aromatic hydrocarbon-based groups comprising an average number of carbon atoms ranging from 1 to 36; wherein R 4  and R 5 , which are identical or different, are groups chosen from saturated or unsaturated, linear or branched, optionally cyclic, optionally aromatic, optionally substituted hydrocarbon-based groups comprising an average number of carbon atoms ranging from 1 to 36, it being possible for R 4  and R 5  to optionally together form a ring, that is optionally substituted; and wherein A is a linear or branched divalent alkyl group comprising an average number of carbon atoms ranging from 2 to 12. 
     
     
         14 . The fiber bundle slurry of  claim 13  wherein the at least two polymer fibers is selected from cellulose acetate, polyamide, PLA, PGA, PEEK, acrylic, polyester, glass, metal, inorganic, poly-3-hydroxybutyrate (PHB), polyhydroxyalkanoates (PHA), Polyamide 11 (PA 11) or any combination thereof. 
     
     
         15 . The fiber bundle of  claim 11  wherein the polymer fibers have an average staple length of at least 4 mm. 
     
     
         16 . The fiber bundle of  claim 11  wherein the polymer fibers have an average staple length of at least 10 mm. 
     
     
         17 . The fiber bundle of  claim 11  wherein the polymer fibers have an average staple length of at least 15 mm. 
     
     
         18 . The fiber bundle slurry of  claim 13  wherein the polymer fibers have an average staple length of at least 4 mm. 
     
     
         19 . The fiber bundle slurry of  claim 13  wherein the polymer fibers have an average staple length of at least 10 mm. 
     
     
         20 . The fiber bundle slurry of  claim 13  wherein the polymer fibers have an average staple length of at least 15 mm.