Methods for producing polymer fibers and polymer fiber products from multicomponent fibers

Abstract

The present invention relates to methods of producing polymer fibers and polymer fiber products and materials recovery from these processes. It is an object of this invention to produce polymer fibers and products that include these fibers using selective dissolution of multicomponent fiber and to recover the dissolved polymer and solvent for subsequent use.

The invention claimed is: 
     
         1 . A method for recycling at least one sacrificial polymer comprising:
 contacting a multicomponent fiber including the at least one sacrificial polymer and at least one target polymer with at least one solvent or at least one swelling agent to separate the at least one target polymer from the at least one sacrificial polymer;   recovering, washing, washing and drying, or drying the at least one target polymer;   separating and recovering at least 50% of the at least one sacrificial polymer from the at least one solvent or the at least one swelling agent;   upon separation of the at least one recovered sacrificial polymer, removing, washing, washing and drying, or drying the at least one recovered sacrificial polymer; and   recovering at least 50% of the at least one solvent or the at least one swelling agent.   
     
     
         2 . The method of  claim 1 , wherein the at least one recovered sacrificial polymer is of the same purity as a virgin polymer of the same chemical composition. 
     
     
         3 . The method of  claim 1 , wherein the at least one recovered sacrificial polymer is operable to be recycled and re-spun. 
     
     
         4 . The method of  claim 1 , wherein the at least one recovered solvent or the at least one recovered swelling agent is operable to be reused to dissolve the at least one recovered sacrificial polymer in a second multicomponent fiber. 
     
     
         5 . The method of  claim 1 , wherein the at least one separated sacrificial polymer is recovered as macromolecules. 
     
     
         6 . The method of  claim 1 , wherein separating and recovering at least 50% of the at least one sacrificial polymer from the at least one solvent or the at least one swelling agent includes recovering at least 75% of the at least one sacrificial polymer from the at least one solvent or the at least one swelling agent. 
     
     
         7 . The method of  claim 1 , wherein separating and recovering at least 50% of the at least one sacrificial polymer from the at least one solvent or the at least one swelling agent includes recovering at least 90% of the at least one sacrificial polymer from the at least one solvent or the at least one swelling agent. 
     
     
         8 . The method of  claim 1 , wherein the at least one sacrificial polymer is recovered as granules or particles. 
     
     
         9 . The method of  claim 1 , wherein the at least one sacrificial polymer includes polystyrene or a polystyrene copolymer. 
     
     
         10 . A system for recycling at least one sacrificial polymer comprising:
 a multicomponent fiber including the at least one sacrificial polymer and at least one target polymer;   at least one solvent or at least one swelling agent operable to separate the at least one target polymer from the at least one sacrificial polymer;   wherein after recovering, washing, washing and drying, or drying the at least one target polymer, at least 50% of the at least one sacrificial polymer is operable to be separated and recovered from the at least one solvent or the at least one swelling agent;   wherein the at least one recovered sacrificial polymer is operable to be removed, washed, washed and dried or dried upon separation of the at least one recovered sacrificial polymer; and   wherein at least 50% of the at least one solvent or the at least one swelling agent is operable to be recovered.   
     
     
         11 . The system of  claim 10 , wherein the at least one recovered sacrificial polymer is of the same purity as a virgin polymer of the same chemical composition. 
     
     
         12 . The system of  claim 10 , wherein the at least one recovered sacrificial polymer is operable to be recycled and re-spun. 
     
     
         13 . The system of  claim 10 , wherein the at least one recovered solvent or the at least one recovered swelling agent is operable to be reused to dissolve the at least one recovered sacrificial polymer in a second multicomponent fiber. 
     
     
         14 . The system of  claim 10 , wherein the at least one separated sacrificial polymer is recovered as macromolecules. 
     
     
         15 . The system of  claim 10 , wherein at least 75% of the at least one sacrificial polymer is operable to be separated and recovered from the at least one solvent or the at least one swelling agent. 
     
     
         16 . The system of  claim 10 , wherein at least 90% of the at least one sacrificial polymer is operable to be separated and recovered from the at least one solvent or the at least one swelling agent. 
     
     
         17 . The system of  claim 10 , wherein at least 75% of the at least one solvent or the at least one swelling agent is operable to be recovered. 
     
     
         18 . The system of  claim 10 , wherein at least 90% of the at least one solvent or the at least one swelling agent is operable to be recovered. 
     
     
         19 . A method for recycling at least one sacrificial polymer comprising:
 separating at least one target polymer from at least one sacrificial polymer of a multicomponent fiber; and   recovering at least 50% of the at least one sacrificial polymer, wherein the at least 50% of the at least one sacrificial polymer is operable to be reused.   
     
     
         20 . The method of  claim 19 , wherein reuse of the at least 50% of the at least one sacrificial polymer includes recycling and re-spinning the at least 50% of the at least one sacrificial polymer.