WO1997027038A1 - Members having a multiaxially oriented coating of thermotropic liquid crystalline polymer and methods and apparatus for producing such members - Google Patents
Members having a multiaxially oriented coating of thermotropic liquid crystalline polymer and methods and apparatus for producing such members Download PDFInfo
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- WO1997027038A1 WO1997027038A1 PCT/US1997/001205 US9701205W WO9727038A1 WO 1997027038 A1 WO1997027038 A1 WO 1997027038A1 US 9701205 W US9701205 W US 9701205W WO 9727038 A1 WO9727038 A1 WO 9727038A1
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Classifications
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/104—Coating to obtain optical fibres
- C03C25/106—Single coatings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/05—Filamentary, e.g. strands
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
- B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
- B29C48/151—Coating hollow articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
- B29C48/154—Coating solid articles, i.e. non-hollow articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
- B29C48/33—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles with parts rotatable relative to each other
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/0003—Moulding articles between moving mould surfaces, e.g. turning surfaces
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/02—Optical fibres with cladding with or without a coating
- G02B6/02395—Glass optical fibre with a protective coating, e.g. two layer polymer coating deposited directly on a silica cladding surface during fibre manufacture
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
- B29L2011/0075—Light guides, optical cables
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K2323/00—Functional layers of liquid crystal optical display excluding electroactive liquid crystal layer characterised by chemical composition
- C09K2323/03—Viewing layer characterised by chemical composition
- C09K2323/035—Ester polymer, e.g. polycarbonate, polyacrylate or polyester
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
- Y10T428/2936—Wound or wrapped core or coating [i.e., spiral or helical]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
- Y10T428/294—Coated or with bond, impregnation or core including metal or compound thereof [excluding glass, ceramic and asbestos]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
Definitions
- MEMBERS HAVING A MULTIAXIALLY ORIENTED COATING OF THERMOTROPIC LIQUID CRYSTALLINE POLYMER AND METHODS & APPARATUS FOR PRODUCING SUCH MEMBERS
- the present invention relates generally to elongated members having a coating of multiaxially oriented thermotropic liquid crystalline polymer (TLCP) , and to methods of, and apparatus for, producing such members.
- TLCP thermotropic liquid crystalline polymer
- Suitable members include glass, plastic, ceramic, or metal rods or fibers, tubes, pipes, or beams. These members may be of any desired length, or indefinite length.
- Rod-like, extended-chain, aromatic-heterocyclic polymers have received considerable interest in both academic and industrial laboratories over the past two decades. These "ordered" polymers include “thermotropic” liquid crystalline polymers, which are modified by temperature changes.
- Thermotropic LCPs are of great interest because they exhibit a partially ordered state that is intermediate between a three-dimensional ordered crystalline state, and the disordered or isotropic fluid state.
- LCPs are anisotropic, i.e. their properties are a function of molecular direction (R.A. Weiss and C.K. Ober, "Liquid Crystalline Polymers," A.C.S. Symposium Series 435 (1990) ) .
- LCPs Structurally many commercial LCPs consist of rigid mesogenic monomer units connected with either flexible spacers or "kink structures" to make them tractable and processable.
- the high degree of molecular order that can be achieved with the LCP molecules allows this material to attain a very tight packing density, similar to a log jam in a river.
- LCPs derive their outstanding properties from this tightly packed rigid-rod formation which at a macroscopic level results in a structure that is self- reinforced through the strong interaction of electron- deficient and electron-rich benzene rings.
- thermotropic LCPs Because of their rigid backbone structure with flexible spacer groups, commercially available thermotropic LCPs have far higher tensile strength and flexural moduli than conventional polymers.
- UVEA Ultraviolet-cured epoxy acrylate
- UVEA coating 3 mil (0.0762 mm) thick which is heavier than a 1 mil (0.0254 mm) TLCP coating and also bulkier, resulting in a limited length of coated fiber which can be accommodated on a spool, carried on an aircraft for payout. This means the object to be guided can be guided only for a shorter distance. Further, UVEA has higher surface friction than TLCP, which means that UVEA tends to cause more "sticking" or "blocking" during unspooling than TLCP. Although thermotropic LCPs possess a variety of properties that make them an attractive candidate for coating purposes, standard LCP processing results in material with uniaxial orientation (all molecules aligned in one direction) .
- Such materials have very good machine (extrusion) direction (MD) mechanical properties and very poor transverse direction (TD) mechanical properties. If standard extrusion techniques are used to extrude LCPs over a tubular structure, the resulting LCP coating with its axial molecular orientation would readily split in the axial direction, when exposed to bending.
- conventional uniaxial TLCP coatings when applied to a flexible optical fiber member, are likely to split along the fiber axis when subjected to bending.
- Such uniaxially oriented material also has a highly negative coefficient of thermal expansion (“CTE”) in the extrusion direction and a highly positive CTE in the transverse direction. This characteristic is generally unacceptable for coating members which will be exposed to thermal cycles. In such cases, it is desirable to have the CTE of the coating more closely approach the CTE of the member.
- the present invention provides a TLCP coating in which the molecules are multiaxially oriented.
- This multiaxially oriented TLCP coating offers both improved resistance to splitting, and closer matching of its Coefficient of Thermal Expansion (CTE) to the CTE of the member.
- CTE Coefficient of Thermal Expansion
- this is accomplished by extruding the TLCP coating onto the elongated member using an extrusion die, in which the TLCP is extruded from an annular gap between an inner mandrel and an outer mandrel, which rotate in opposite directions with respect to each other. This counter-rotation causes transverse shear to provide the multiaxial orientation.
- Some of the molecules are aligned at an angle to the axis of extrusion, so if the biaxial or multiaxial coating is nicked at one point, the nick is unlikely to propagate, and develop into a split along the longitudinal axis of the member, as would likely occur in a uniaxial coating, in which the molecules align parallel to the axis.
- TLCP material in which a positive orientation value + ⁇ has a different absolute value from a negative orientation value - ⁇ , within the range mentioned above, to strengthen the coating or change its CTE in a particular direction.
- circumferential or hoop stress is twice the stress in the longitudinal direction; for such an application, one could run the outer die mandrel fast enough to obtain relatively high multiaxial orientation on one surface for high transverse (hoop) strength, and run the inner mandrel slow enough to obtain less multiaxial orientation on the other surface and more axial strength than would be provided by an equally multiaxial orientation. Conversely, one could run the inner mandrel faster.
- the multiaxially oriented coatings of the present invention as compared with uniaxially oriented coatings, possess desirable properties, including:
- the improved properties possessed by the multiaxially oriented TLCP coatings of the present invention mean that one can provide the same or better protection to the coated member than a thicker layer of a prior art coating provides, so that, applied to an optical fiber, the TLCP coating could for example provide a 60 percent reduction in linear mass density, compared to a standard, 3-mil (0.0762 mm) thick, coating of UVEA on such an optical fiber.
- the TLCP coating could therefore wrap a longer length of coated fiber onto a spool. Due to the reduction in weight per unit length, one could deploy a greater length of coated fiber, for example from an aircraft.
- Multiaxial orientation can be used to "tailor" the CTE of the LCP coating. This is possible because the CTE of the LCP molecule in the fibril or axial direction is typically negative (-7 to -12 ppm/°C) and in the transverse direction is positive (+50 to +100 ppm/°C) .
- the CTE of multiaxial coatings can be varied from a slightly negative value (uniaxial orientation) to a relatively high positive value by increasing the degree of multiaxial orientation. This permits matching the CTE of the coating to the CTE of the member to which the coating will be applied. This is desirable because, as is well known, any mismatch between the CTE of a member and its coating has a tendency, when temperature changes, to cause separation or delamination at the interface or boundary between the two materials. This is particularly true if the temperature change is repeated or cyclic, for example, in an outdoor environment where temperature is high during daylight hours and low at night. In lunar or other space environments, such changes can be sudden.
- FIG. IA is a bar graph illustrating the n-fold improvement in certain properties, of thermotropic LCP, compared to UVEA;
- FIG. IB is a schematic perspective view of a multiaxially oriented LCP coating, applied to an optical fiber;
- FIG. 2 illustrates the difference between uniaxial orientation and multiaxial orientation, in a single-layer LCP
- FIG. 3 is a graph illustrating the results of a Differential Scanning Calorimetric ("DSC") analysis of VECTRA ® , a wholly aromatic copolyester thermotropic LCP ;
- DSC Differential Scanning Calorimetric
- FIG. 4 is a schematic diagram of a suitable apparatus for supplying liquid TLCP to the counter- rotating die
- FIG. 5 is a schematic diagram of the counter- rotating die, showing the inner and outer rotors or mandrels;
- FIG. 6 is a graph illustrating the differences in tensile strength, in machine direction (MD) and in transverse direction (TD) , between UVEA film and multiaxially oriented VECTRA ® film;
- FIG. 7 is a graph of the relationship between tensile modulus and the extent of multiaxial orientation of VECTRA ® film
- FIG. 8 is a graph of the relationship between percentage elongation to break and the extent of multiaxial orientation
- FIG. 9 is a graph of the relationship between CTE and the extent of multiaxial orientation
- FIG. 10 is a cross-sectional view, illustrating the extrusion of multiaxial TLCP coating onto an optical fiber
- FIG. 11 is a side view of an inner mandrel of an extrusion die, on which a feeding zone or set of spiral grooves has been formed;
- FIG. 12 is a cross-sectional view along section line L -- L of FIG. 11, illustrating how the grooves are shaped.
- Fig. 13 is a graph showing comparative results of extrusion operations with and without grooved feed zones in the die.
- FIG. IA illustrates four ways in which thermotropic LCP is superior to UV-cured epoxy acrylates (UVEA) , a prior art coating material.
- UVEA UV-cured epoxy acrylates
- the UVEA tested was DeSolite ® 950-008, four mils (0.1016 mm) thick.
- TLCP provides a reduction in moisture permeation, a reduction in moisture absorption, an increase in tensile strength, and a reduction in mismatch of respective coefficients of thermal expansion (CTE) between the coating and a member, for example glass.
- FIG. IB illustrates schematically a coating of thermotropic liquid crystalline polymer (TLCP) applied to a generally cylindrical member, in this example an optical fiber.
- TLCP thermotropic liquid crystalline polymer
- the criss-crossing helical lines indicate that the inventive method used to extrude the coating has caused the long-chain polymer molecules to align along at least two diverging directions within the single coating ply. This is defined as "biaxial" orientation of the molecules. These directions need not be constant along the longitudinal axis of the member and extrudate ("machine direction”) , but rather can rotate. The direction normal to the axis of extrusion (i.e., radial direction) is known as the "transverse direction.”
- multiaxially oriented TLCP material characteristics will be important in understanding the present invention: balanced biaxial a material having maximum strength and stiffness at approx. ⁇ 45 deg. of the machine direction, but exhibiting the least angular dependence of these properties.
- FIG. 2 shows the morphology of oriented LCP coatings.
- Novel LCP extrusion technologies disclosed, e.g. in
- the rotation of the counter-rotating mandrels creates transverse shear flows that are superimposed on the axis shear developed as the polymer melt is extruded through the die.
- the angle that the LCP fibrils make with the longitudinal axis of the tubular extrudate can be readily varied from ⁇ 5 to ⁇ 75 degrees.
- the die rotation speed is directly proportional to the rate at which the member is fed through for coating, e.g. the optical fiber drawing rate in the case of coating optical fiber.
- the extrusion die would have its axis oriented vertically.
- the extrusion die could have its axis oriented horizontally.
- Adhesives may be added between the layers by alternating adhesive extruders and LCP extruders along a production line.
- a variety of adhesives useful for adhering a TLCP to a surface are known, and may be used for this purpose.
- the method will work with members having oval, rectangular, polygonal, or other essentially regular cross-section.
- supplemental steps would likely be required to bring the coating into contact with the inside corners or other recesses in the member being coated.
- coating an I-beam shape might require application of suction or vacuum just after the extruded TLCP leaves the die discharge gap, to pull the TLCP toward the member, or application of external air pressure or the like, to push the TLCP onto the member.
- a hexagonal array of radially inwardly directed airjets would be suitable.
- thermotropic LCPs for use in the present invention include wholly and partially aromatic polyesters and copolyesters such as those disclosed in U.S. Patent Nos. 3,991,014, 4,067,852, 4,083,829, 4,130,545, 4,161,470, 4,318,842, and 4,468,364.
- Preferred thermotropic LCPs include wholly or partially aromatic polyesters or copolyesters.
- Particularly preferred wholly aromatic and partially aromatic copolyesters comprise 6-oxy-2-naphthoyl moieties and p-oxybenzoyl moieties.
- Particularly preferred copolyesters include VECTRA ® , ZENITE ® (E.I.
- thermotropic liquid crystal polymers include SUMIKASUPER ® and EKONOLTM (Sumitomo Chemical) , DuPont HXTM, RODRUN ® (Unitika) and GRANLARTM (Grandmont) .
- VECTRA ® a wholly aromatic copolyester sold by
- VECTRA ® Hoechst Celanese Advanced Materials Group, Summit, New Jersey, is one particularly preferred TLCP for use in the present invention.
- VECTRA ® is commercially available with varying amounts of 6-oxy-2-naphthoyl and p-oxybenzoyl moieties, with various fillers, and in various grades.
- VECTRA ® A950 is a particular neat (unfilled) resin.
- VECTRA A900 was formerly a more highly filtered grade than VECTRA A950, but A950 is now just as filtered, and is reported to be essentially the same material chemically. Use of the grade designation "A900” is believed to have been discontinued. Therefore, the term “VECTRA A950" is used in the following description, although some of the Figures refer to A900.
- VECTRA ® A950 is reported to be the most ductile grade in the VECTRA product line. This polymer has been reported to consist essentially of about 25-27 percent of 6-oxy-2-naphthoyl moieties and about 73-75 percent of p- oxybenzoyl moieties, as described in example 4 of U.S. Patent No. 4,468,364 and in G.W. Calundann et al., "Anisotropic Polymers, Their Synthesis and Properties", reprinted from Proceedings of the Robert A. Welch Conferences on Chemical Research, XXVI Synthetic Polymers, November 15-17, 1982, Houston, Texas, pp. 247- 291 (see especially pp. 263-265) .
- FIG. 3 is a graph illustrating the results of a Differential Scanning Calorimetric ("DSC") analysis of DSC
- VECTRA ® A950 has a relatively wide melt-processing temperature range "window" of about 269° C to about 285° C, indicated by the rise shown in heat flow (mW) .
- VECTRA A950 has a specific gravity of 1.4, a tensile strength of 85,000 psi (5.86 x IO 9 N/m 2 ) , a tensile modulus of about 6,000,000 psi (4.14 x IO 18 N/m 2 ), and a melting point of 535° F or 296° C. It has a melt viscosity at 570°F (300°C) of about 600 poise.
- CTE bulk coefficient of thermal expansion
- thermotropic LCP is ZENITE ® .
- This polymer has been reported to consist of hydroxy- benzoic acid/phenyl hydroquinone/dimethyl-napthylene dicarboxylate units.
- FIG. 4 is a schematic showing system components of one extrusion system that can be used in the practice of the present invention.
- a desiccant dryer bin removes moisture from the LCP pellets, prior to their being fed into the extruder.
- a single-screw metering auger connected to the bottom of the bin, volumetrically feeds pellets into the extruder at a controlled rate.
- a pointed tip high compression extruder screw generates shear and eliminates dead spots at the exit of the extruder.
- the extruder itself is a Killion laboratory scale model with a 1 in. (2.54 cm) diameter screw and a 24 in. (61 cm) long barrel.
- the extruder has three zones, each with its own heaters. The first is the feed zone where melting begins. The beginning of this zone is water-cooled at the throat to prevent material bridging. A compression zone is used to completely melt the pellets and to pressurize the melt. The last zone is used to generate high levels of shear and provide a reasonable level of throughput control.
- a coarse filter removes degraded material and nonmelted particulates (50 to 100 - 15 - ⁇ ) from the melt.
- the coarse filter preferably comprises 200 mesh wire screen, sandwiched between two 80 mesh screens and supported by a breaker plate.
- a gear pump accurately meters the melt into the counter-rotating die at a controlled feed rate and steady pressure.
- the gear pump preferably is housed in a large block which contains heaters and instrumentation to monitor pump pressure and the melt temperature.
- a fine filter removes particles whose size is 10 micrometers or larger (degraded material and non- melted particulates) from the LCP melt.
- the gear pump feeds a counter-rotating die, shown in FIG. 5, which provides additional shear thinning and a controlled degree of multiaxial orientation to the extrudate.
- the basic design of this die utilizes bearings and a drive system which are located above and isolated from the melt flow path of the polymer. This design feature protects components from the high processing temperatures associated with thermoplastic/thermotropic melts (up to 800° F or 427° C) .
- Melted LCP enters the die at a point below the lowest bearing and is directed into the annulus, between the counter-rotating mandrels, where the LCP is exposed to shear thinning.
- Metal piston rings are used to seal and prevent the melt flow from traveling up between the counter-rotating mandrels.
- Metal piston rings in combination with bleed holes are used to prevent melt flow from passing into the gap between the die housing and the outer rotating mandrel.
- Electric heaters are mounted on the die housing and melt flow block.
- a take-up system assists the extrusion process by generating controlled pultrusion.
- the take-up system for films consists of two variable-speed, chrome-plated pinch rollers; in the case of coatings, a member advancing system is used.
- the elongated member is advanced through the die faster than the TLCP is extruded, so that the tension exerted on the extruded TLCP helps to draw it down onto the surface of the member, and to form a coating of the desired thickness.
- Temperature controllers with feedback are integrated into the following components: desiccant dryer, three extruder locations, coarse filter, pump block and the top and bottom of the counter-rotating die. Pressure transducers are located at critical points to help monitor the characteristics of the melt, protect equipment from plugging, and control residence time in the extruder. Pressure transducers are located at the following locations: discharge of extruder just before the coarse screen, pump inlet and die inlet.
- Conditions suitable to achieve the desired degree of multiaxial orientation of the TLCP coatings of the present invention can be determined for the particular TLCP and extrusion system, for example, by extruding multiaxially oriented TLCP films.
- Extruder zone 1 480° F (249°C)
- Extruder zone 2 510° F (266°C)
- Extruder zone 3 520° F (271°C)
- Pump block 530° F (277°C)
- FIG. 13 is a graph of results of tests of VECTRA ® film, 2 mil (0.0508 mm) thick, produced with settings for varying degrees ⁇ of multiaxial orientation, with and without a spiral feed zone.
- the y axis indicates peak tensile strength (kpsi) , in machine direction (MD) and in transverse direction (TD) .
- the solid circles (MD) and squares (TD) indicate results without a spiral feed zone, on a first die.
- the open circles (MD' ) and squares (TD' ) indicate results on a second die, with a spiral feed zone.
- the depth and number of the grooves useful in achieving the desired multiaxial orientation with a particular die configuration and a particular TLCP can be readily determined by the skilled artisan, for example, by extruding and testing film, as described below in connection with determining the processing conditions to achieve a desired multiaxial orientation.
- the spirals on one mandrel would be threaded the opposite way from the spirals on the other facing mandrel surface.
- the depth of the grooves compared to the distance between the inner diameter (ID) of the outer mandrel and the maximum outer diameter (OD) of the inner mandrel, falls in a range between about 0 % at the end of the spiral feed zone to about 600 % of the distance, at the beginning of the spiral feed zone.
- FIG. 11 illustrates schematically how the inner mandrel of the extrusion die referred to above was formed with a "spiral feeding zone" or set of spiral grooves. Eight spiral grooves, equally spaced around the circumference of the inner mandrel, were formed. The bottom of each groove was maintained at a constant radius Rl (0.575 inches or 1.4605 cm, i.e. diameter 1.15 inches or 2.921 cm) from the central axis of the mandrel, but the depth of the grooves decreased in the melt flow direction by varying the radius of the peak surface (i.e. the outermost diameter) of each groove from a maximum radius R2 (0.6175 inch or 1.568 cm, i.e.
- the processing parameters will al ⁇ o depend upon the particular TCLP to be extruded.
- the LCP retention time is up to 10 minutes, but preferably less than 5 minutes, and most preferably less than 3 minutes. Longer retention times typically result in material degradation.
- Multiaxially oriented TCLP film was produced, to determine the properties of TLCPs made with various parameter settings, and processing conditions for coating elongated members.
- VECTRA ® pellets were conditioned in the desiccant dryer at 150° C for 4 hours. The pellets were then fed into the extruder through a metering auger. "Extruder starve" feeding conditions were maintained at all times. A high-compression screw, 6:1 ratio, was used to create maximum shear in the melting zone. The extruder operated at 84 RPM (Revolutions Per
- the extruder had a barrel length L of 24 inches (60.96 cm) , and a screw diameter D of 1 inch (2.54 cm) and an L/D ratio of 24/1.
- the pump was large enough to provide a flow of TLCP exceeding 33 grams/minute. Sufficient lengths of multiaxially oriented film at each of the four desired orientations was produced. Selected samples from each of the four film extrusion runs were tested for tensile strength, modulus and elongation-to-break, according to the standard ASTM D882 of the American Society of Testing Materials. The highest machine direction and lowest transverse direction tensile strength and modulus are found when there is a low degree of biaxial orientation. As the biaxiality approaches ⁇ 45°, the machine-direction and transverse-direction values of tensile strength and modulus converge, as shown in FIGS. 6 and 7, respectively. As shown in FIG. 8, the percent elongation at failure (break) in the machine and transverse directions also converges as the multiaxial orientation approaches ⁇ 45 degrees.
- the CTE matches that of glass (0.5 ppm/°C) .
- the CTE of UVEA a standard coating used on optical fibers for guiding line- of-sight missiles, is 123 ppm/°C.
- Moisture permeability was measured according to ASTM F1249.
- Moisture absorption was measured according to ASTM D570, and was found to be about 100 times lower for multiaxially oriented TLCP than for UVEA. See FIG. IA, second column.
- TLCP coatings onto elongated essentially non-planar members such as glass rods
- the TLCP was coated continuously and seamlessly onto the surface of the elongated member.
- suitable members are glass optical fibers, solid and hollow rods of glass and other materials, pipes, beams, and the like. Almost any elongated structure can be coated, as long as its cross-section is reasonably regular, e.g. rounded or polygonal.
- Extruder zone 2 510° F (266°C)
- Extruder zone 3 520° F (271°C)
- Pump block 530° F (277°C)
- the glass rods Prior to being coated, the glass rods were etched with a 7-percent hydrofluoric (HF) acid solution. Four of the five glass rods were heated to 510° F (265° C) to match the temperature of the exiting melt, and to improve adhesion.
- HF hydrofluoric
- a one inch (2.54 cm) diameter single-screw extruder and a 2.5 cc/rev. gear pump were used.
- the extruder and pump were operated at 81.8 RPM and 50 RPM, respectively.
- the take-up speed or production rate was 62 inches (157.5 cm) per minute.
- the heated rods were uniformly coated with 1.5 mil (0.00381 cm) thick VECTRA ® .
- the glass rods were heated, because of the relatively low rate of extrusion used, to avoid premature solidification of the TLCP coating; the low rate of extrusion was used to get a higher ⁇ which resulted in a CTE that approached the CTE of the glass member (0.5 ppm/°C) . See FIG. 9, in which the da ⁇ hed line indicates the CTE of glass.
- Similar equipment scaled down proportionately because of the smaller member diameter, would be used.
- a faster extrusion rate would be used.
- a vertical extrusion die axis would preferably be used since fiber drawing towers are oriented vertically and it would be most efficient to coat the fiber as it is produced.
- the optical fiber would have a diameter not exceeding about 125 microns and the coating would have a thickness not exceeding about 100 microns, preferably not exceeding about 25 microns.
- a multiaxially oriented coating of VECTRA ® A-950 was applied to the outer surface of polyethylene tubing, having an outer diameter of 1.1 inch (2.794 cm) and an inner diameter of 0.85 inch (2.159 cm), using a counter-rotating die similar to that shown in FIG. 5.
- the equipment used was as follows: Extruder type: twin-screw, co-rotating, 25 mm diameter screws;
- Melt pump type 2.92 cc/revolution; Extrusion die: counter-rotating, inner diameter 1.25 inch (3.175 cm) , die gap 0.015 inch (0.0381 cm) .
- Example 4 Thickness of 0.0019 to 0.0023 inch 0.0019 to 0.0023 inch coating: (0.04826-0.05842 mm) (0.04826- 0.05842 mm) Orientation: ⁇ 6 degrees ⁇ 10 degrees
- Extruder RPM: 60 Melt pump RPM: 20 20 Outer Mandrel RPM: 10 18 Inner Mandrel RPM: 10 18
- thermotropic LCPs capable of being multiaxially oriented may exist, or may be hereafter developed, and the method may be found useful for coating members other than elongated members. Further, various methods of bringing the extrudate into contact with the member may be developed.
- the multiaxial orientation of the TLCP coating can be solidified by physical, chemical, or thermal means known to those skilled in the art.
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP97903968A EP0954428A4 (en) | 1996-01-26 | 1997-01-24 | Members having a multiaxially oriented coating of thermotropic liquid crystalline polymer and methods and apparatus for producing such members |
AU18392/97A AU1839297A (en) | 1996-01-26 | 1997-01-24 | Members having a multiaxially oriented coating of thermotropic liquid crystalline polymer and methods and apparatus for producing such members |
CA002259363A CA2259363C (en) | 1996-01-26 | 1997-01-24 | Members having a multiaxially oriented coating of thermotropic liquid crystalline polymer and methods and apparatus for producing such members |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/590,565 | 1996-01-26 | ||
US08/590,565 US5882741A (en) | 1996-01-26 | 1996-01-26 | Members having a multiaxially oriented coating of thermotropic liquid crystalline polymer and method and apparatus for producing such members |
Publications (1)
Publication Number | Publication Date |
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WO1997027038A1 true WO1997027038A1 (en) | 1997-07-31 |
Family
ID=24362743
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US1997/001205 WO1997027038A1 (en) | 1996-01-26 | 1997-01-24 | Members having a multiaxially oriented coating of thermotropic liquid crystalline polymer and methods and apparatus for producing such members |
Country Status (5)
Country | Link |
---|---|
US (1) | US5882741A (en) |
EP (1) | EP0954428A4 (en) |
AU (1) | AU1839297A (en) |
CA (1) | CA2259363C (en) |
WO (1) | WO1997027038A1 (en) |
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WO2007127274A1 (en) * | 2006-04-27 | 2007-11-08 | E. I. Du Pont De Nemours And Company | Polymeric pipes and containers with high barrier layers |
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JP2001172479A (en) * | 1999-12-16 | 2001-06-26 | Sumitomo Chem Co Ltd | Liquid crystal polyester resin composition and its molded product |
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US20030009151A1 (en) * | 2001-07-03 | 2003-01-09 | Scimed Life Systems, Inc. | Biaxially oriented multilayer polymer tube for medical devices |
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US7963126B2 (en) * | 2008-03-05 | 2011-06-21 | The Boeing Company | Glass fibers having improved durability |
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WO2007127274A1 (en) * | 2006-04-27 | 2007-11-08 | E. I. Du Pont De Nemours And Company | Polymeric pipes and containers with high barrier layers |
Also Published As
Publication number | Publication date |
---|---|
CA2259363A1 (en) | 1997-07-31 |
US5882741A (en) | 1999-03-16 |
EP0954428A1 (en) | 1999-11-10 |
AU1839297A (en) | 1997-08-20 |
EP0954428A4 (en) | 2001-10-10 |
CA2259363C (en) | 2002-01-15 |
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