An apparatus for improved coagulation injection during the manufacture of polymer fibers, and method of use thereof

Abstract

The present disclosure relates to a cyclone-producing apparatus for use in the production of polymer fibers, such as large tow polymer fibers, typically used in the manufacture of carbon fiber. The present disclosure also relates to a system comprising the cyclone-producing apparatus and a process for producing polymer fibers using such a system. The polymer fibers produced are useful for the manufacture of carbon fiber, which finds application as structural components in composite materials relevant to many areas, such as the aerospace, marine, and automotive industries, among others.

1 . A cyclone-producing apparatus for use in the production of polymer fibers, the cyclone-producing apparatus comprising:
 a cylindrical housing having a closed proximal end and an open distal end, and   an inlet connected to the proximal end of the cylindrical housing, the interior of said inlet being fluidly connected to the interior of the cylindrical housing,   wherein the inlet is oriented tangentially to the body of the cylindrical housing.   
     
     
         2 . The cyclone-producing apparatus according to  claim 1 , further comprising a spinneret housing adapted to accept a spinneret or spinneret assembly, wherein the spinneret housing is secured, typically removably, to the open distal end of the cylindrical housing and comprises one or more openings that are coaxial with and fluidly connected to the interior of the cylindrical housing. 
     
     
         3 . The cyclone-producing apparatus according to  claim 1 , wherein the cylindrical housing further comprises an opening fluidly connected to the interior of the cylindrical housing, wherein the opening has a profile, which is adapted to the shape of a dope supply line. 
     
     
         4 . The cyclone-producing apparatus according to  claim 1 , wherein the cyclone-producing apparatus further comprises a barrier plate extending radially outward from the open distal end of the cylindrical housing, extending to the top, bottom, and sides of a coagulation bath. 
     
     
         5 . The cyclone-producing apparatus according  claim 1 , wherein the cyclone-producing apparatus further comprises means for removably securing the cyclone-producing apparatus to the walls of a coagulation bath, and holes that are complementarily threaded for screws used to push against the walls of the coagulation bath and/or tabs having such holes. 
     
     
         6 . The cyclone-producing apparatus according to  claim 1 , wherein the cyclone-producing apparatus is a combination of two or more parts secured together. 
     
     
         7 . The cyclone-producing apparatus according to  claim 1 , wherein the length of the cylindrical housing is 1.3D to 1.5D, wherein D is the diameter of the cylindrical housing. 
     
     
         8 . A system for producing polymer fibers, the system comprising:
 a) the cyclone-producing apparatus according to  claim 1 ,   b) a polymer dope supply line,   c) a spinneret or spinneret assembly, and   d) a coagulation bath comprising coagulation liquid.   
     
     
         9 . The system according to  claim 8 , wherein the spinneret or spinneret assembly is removably secured in a spinneret housing, which is removably secured to the open distal end of the cylindrical housing and comprises one or more openings that are coaxial with and fluidly connected to the interior of the cylindrical housing. 
     
     
         10 . The system according to  claim 9 , wherein the polymer dope supply line passes through an opening fluidly connected to the interior of the cylindrical housing, wherein the opening has a profile, which is adapted to the shape of the dope supply line and the polymer dope supply line is connected to the inlet of the spinneret. 
     
     
         11 . The system according to  claim 8 , wherein the cyclone-producing apparatus is removably secured to the walls of the coagulation bath with screws passing through complementarily threaded holes and/or tabs having such holes on the cyclone-producing apparatus and that push against the walls of the coagulation bath. 
     
     
         12 . A process for the production of polymer fibers, the process comprising: a′) providing the system according to  claim 1 , and
 b′) spinning a polymer dope, which is supplied through the polymer dope supply line to the spinneret or spinneret assembly, into the coagulation bath; 
 wherein coagulation liquid is pumped into the inlet connected to the proximal end of the cylindrical housing of the cyclone-producing apparatus. 
 
     
     
         13 . The process according to  claim 12 , wherein the variability in filament diameter and/or circularity is reduced by 5 to 50% compared to the variability in filament diameter and/or circularity obtained in a process in which the cyclone-producing apparatus is absent. 
     
     
         14 - 22 . (canceled)