Patent GB-786755-A (GB)
Title: Spinning process
IPC: D01D5/06
Filed: 1955-02-16
Abstract: Shaped products of vinylidene polymers are made by forming a stable aqueous dispersion containing at least 20 per cent of the polymer with the aid of an emulsifying agent, the dispersed particles having an average size below 2 microns, preferably below 1 micron, and passing the dispersion through an orifice into an aqueous coagulating bath having a pH of at least 8, preferably at least 12, whereby the polymer particles are coagulated into a self-supporting shaped product.  The product is then removed from the bath and heat-treated so that it is dried and brought to a temperature above its second order transition temperature (Tg), so as to cause the particles to coalesce, and stretched at this temperature to produce an amorphous molecularly oriented product. The polymers used must have a Tg of 25-100 DEG  C., preferably 40-70 DEG  C., must have an average molecular weight of at least 50,000 and desirably up to 2,000,000, and must comprise a major proportion, on a molar basis, of nitrogen- and/or oxygen-containing groups which are capable of being hydrolysed with strong aqueous alkali.  Representative and preferred dymers among many specified are copolymers of acrylonitrile with ethyl acrylate, with methyl acrylate, and with butoxyethyl acrylate, copolymers of methyl methacrylate with ethyl acrylate, and copolymers of vinyl acetate with ethyl methacrylate.  The dispersions may be prepared by polymerizing in situ suitable monomers or monomer mixtures, which may also contain minor proportions of other vinyl monomers which have the function of "building up" the polymer or copolymer.  Preferred examples of such monomers, among many listed, are 5-hydroxypentyl vinyl ether, ureidoisobutyl vinyl ether, N-(a -methacrylamidopropyl) - hexahydro - 2 - pyrimidone, N - methyl - vinoxyethyl melamine, 2-hydroxyethyl vinyl sulphide, aminoisobutyl vinyl ether, b -aminoethyl vinyl ether, glycidyl methacrylate, 5-formamidopentyl vinyl ether, and ureidopentyl vinyl ether. Suitable polymerization initiators and catalysts are benzoyl peroxide, tert.-butyl hydroperoxide, cumene hydroperoxide, tetralin peroxide, acetyl peroxide, caproyl peroxide, tert.-butyl perbenzoate, methyl ethyl ketone peroxide, azo-diisobutyronitrile, dimethyl azodiisobutyrate, or ammonium, sodium, or potassium persulphate, particularly when these salts are used in the presence of a reducing agent.  The resulting polymer dispersions have a relatively low viscosity and may be passed through orifices into the coagulating bath without the use of high pressure.  The coagulating bath, which is preferably maintained at 30-105 DEG  C., may contain lithium, sodium, or potassium chloride, sodium or potassium sulphate or formate, sodium acetate or phosphate, urea or glucose.  The pH may be adjusted by the addition of alkali metal or quaternary ammonium hydroxides, and the bath may have a total electrolyte content of 5-50 per cent, preferably 10-40 per cent.  Generally, for polymers of higher Tg, a higher bath temperature and pH give better results. After leaving the bath the product may be washed with water or dilute acid, preferably aqueous organic acid, and heated, either before or after this wash, to 100-250 DEG  C., at which temperature coalescence of the particle, but not melting, occurs.  Either during or after this "fuse-drying" the product may be stretched to the extent of 50-2000 per cent at 80-250 DEG  C. and may then be wound up.  If desired, the polymers may be selected to contain reactive groups such as amido, ester, carbamate, azlactone, anhydride, methylene halide, acyl, amino or isocyanate groups, but preferably the hydroxyl, carboxyl, or epoxy, group, and the shaped polymer may be reacted with a polyfunctional and complementally reactive reagent which creates cross-linkages and so promotes dimensional stability.  This reagent, which may be a diisocyanate, a polycarboxylic acid or its anhydride or acid halide or, preferably, a polyamine such as ethylene diamine, is selected for the particular reactive groups present in the polymer, and may be applied at any stage of the process subsequent to the coagulating bath in the presence of a suitable catalyst, such as an ammonium salt, or a urea and/or formaldehye derivative.  The reagent may be employed in the form of an aqueous solution, a non-aqueous solution, as a melt, or in the vapour phase.  In a modification of this last feature of the invention, the polymer dispersion extruded into the coagulating bath may comprise at least two different polymers which have the complementally reactive groups indicated, or alternatively one polymeric species may contain two different and complementally reactive groups, these groups being made to form cross-linkages as already described.  Specification 747,184 is referred to.