Charles Garry Helms

US Patent:

20010000234, Apr 12, 2001

Filed:

Dec 8, 2000

Appl. No.:

09/731656

Inventors:

Charles Helms - Asheville NC, US
Dominick Burlone - Asheville NC, US
James Huff - Mars Hill NC, US
Thomas Kessler - Schifferstadt, DE

Assignee:

BASF Corporation

International Classification:

B32B003/10

US Classification:

428/131000, 428/402000

Abstract:

This invention provides an apparatus and method for injecting an additive directly into a polymer melt stream. The method comprises supplying a melt flow of a polymeric host material to a die assembly having a thin-plate assembly and injecting at least one additive into at least one predetermined location in a cross-section of the melt flow of the polymeric host material while the melt flow passes through the die assembly. The method achieves uniform dosing of the one or more additives in the extrusion direction in the polymeric host material without homogeneously mixing the one or more additives and the polymeric host material. The apparatus for directly injecting one or more additives into a polymer melt stream comprises a pumping system, a die assembly having a thin-plate assembly, and a distribution line.

US Patent:

20010009941, Jul 26, 2001

Filed:

Feb 27, 2001

Appl. No.:

09/793445

Inventors:

Charles Helms - Asheville NC, US
Dominick Burlone - Asheville NC, US
James Huff - Mars Hill NC, US
Thomas Kessler - Schifferstadt, DE

Assignee:

BASF Corporation.

International Classification:

C08K005/04
A23G003/12

US Classification:

524/400000, 425/381200

Abstract:

This invention provides an apparatus and method for injecting an additive directly into a polymer melt stream. The method comprises supplying a melt flow of a polymeric host material to a die assembly having a thin-plate assembly and injecting at least one additive into at least one predetermined location in a cross-section of the melt flow of the polymeric host material while the melt flow passes through the die assembly. The method achieves uniform dosing of the one or more additives in the extrusion direction in the polymeric host material without homogeneously mixing the one or more additives and the polymeric host material. The apparatus for directly injecting one or more additives into a polymer melt stream comprises a pumping system, a die assembly having a thin-plate assembly, and a distribution line.

US Patent:

20020052452, May 2, 2002

Filed:

Jun 13, 2001

Appl. No.:

09/879058

Inventors:

Dominick Burlone - Asheville NC, US
Matthew Hoyt - Brownstown Township MI, US
Charles Helms - Greenwood SC, US
John Hodan - Arden NC, US
Richard Kotek - Raleigh NC, US
Carol Morgan - Asheville NC, US
Randall Sferrazza - Asheville NC, US
Fang Wang - Arden NC, US
Otto Ilg - Asheville NC, US
Terry Roberts - Candler NC, US
Ronald Morrow - Enka NC, US

Assignee:

BASF Corporation

International Classification:

C08F026/00

US Classification:

526/065000, 526/312000

Abstract:

Continuous anionic polymerization and melt-spinning of a polycaprolactam includes forming a reaction mixture by bringing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator into contact with one another, and then subjecting the reaction mixture to anionic polymerization reaction conditions to obtain a molten polycaprolactam. The molten polycaprolactam is the directly (i.e., without intermediate solidification) transferred to, and extruded through, a fiber-forming orifice of a spinneret to form a fiber thereof. One exemplary system to achieve such continuous anionic polymerization and melt-spinning of polycaprolactam includes a mixer for receiving and mixing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator, and a reactor and melt-spinning apparatus downstream of the mixer. The reactor and melt-spinning apparatus most preferably is formed of multiple plates which establish a reactor zone having a flow path for the reaction mixture which is sized and configured to achieve a predetermined residence time of the reaction mixture therein, and a temperature control zone in thermal communication with the reactor plate for controlling the temperature of the reaction plate to achieve anionic polymerization reaction conditions while the reaction mixture is flowing along the defined flow path therein to obtain the molten polycaprolactam. A spinneret zone downstream of the reactor zone thus receives the molten polycaprolactam directly and forms a fiber therefrom by extruding it through the spinneret's fiber-spinning orifice.

US Patent:

20020058761, May 16, 2002

Filed:

Jun 13, 2001

Appl. No.:

09/879066

Inventors:

Dominick Burlone - Asheville NC, US
Matthew Hoyt - Brownstown Township MI, US
Charles Helms - Greenwood SC, US
John Hodan - Arden NC, US
Richard Kotek - Raleigh NC, US
Carol Morgan - Asheville NC, US
Randall Sferrazza - Asheville NC, US
Fang Wang - Arden NC, US
Otto Ilg - Asheville NC, US
Terry Roberts - Candler NC, US
Ronald Morrow - Enka NC, US

Assignee:

BASF Corporation

International Classification:

C08F002/00

US Classification:

526/065000, 526/089000, 528/480000, 264/172170, 264/172180, 264/176100, 264/205000, 264/209700

Abstract:

Continuous anionic polymerization and melt-spinning of a polycaprolactam includes forming a reaction mixture by bringing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator into contact with one another, and then subjecting the reaction mixture to anionic polymerization reaction conditions to obtain a molten polycaprolactam. The molten polycaprolactam is the directly (i.e., without intermediate solidification) transferred to, and extruded through, a fiber-forming orifice of a spinneret to form a fiber thereof. One exemplary system to achieve such continuous anionic polymerization and melt-spinning of polycaprolactam includes a mixer for receiving and mixing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator, and a reactor and melt-spinning apparatus downstream of the mixer. The reactor and melt-spinning apparatus most preferably is formed of multiple plates which establish a reactor zone having a flow path for the reaction mixture which is sized and configured to achieve a predetermined residence time of the reaction mixture therein, and a temperature control zone in thermal communication with the reactor plate for controlling the temperature of the reaction plate to achieve anionic polymerization reaction conditions while the reaction mixture is flowing along the defined flow path therein to obtain the molten polycaprolactam. A spinneret zone downstream of the reactor zone thus receives the molten polycaprolactam directly and forms a fiber therefrom by extruding it through the spinneret's fiber-spinning orifice.

US Patent:

62323717, May 15, 2001

Filed:

May 11, 1998

Appl. No.:

9/075169

Inventors:

Donald Caswell - Anderson SC
Frank R. Jones - Asheville NC
David B. Ledford - Arden NC
Stanley A. McIntosh - Candler NC
Gary W. Shore - Asheville NC
Karl H. Buchanan - Arden NC
Wayne S. Stanko - Asheville NC
G. Daniel Gasperson - Candler NC
Charles F. Helms - Asheville NC

Assignee:

BASF Corporation - Mt. Olive NJ

International Classification:

C08K 900

US Classification:

523205

Abstract:

Polymeric compositions include a nonaqueous additive system having dispersant-coated pigments physically dispersed in a liquid nonaqueous polymeric carrier which may be added directly to a melt flow of a polymeric host material. The additive system employed in the polymeric systems is most preferably in the form of a particulate paste which can be added in metered amounts (dosed) to a melt flow of the polymeric host material prior to being spun into filaments. By providing a number of additive systems having a number of different additive attributes, and controllably dosing one or more into the melt flow of host polymeric material, shaped objects of the polymeric material (e. g. , melt-spun filaments) having different additive attributes may be produced on a continuous basis without shutting down the shaping operation.

US Patent:

58074902, Sep 15, 1998

Filed:

Mar 26, 1996

Appl. No.:

8/621637

Inventors:

Michael A. Davis - Asheville NC
Jeffrey S. Dugan - Asheville NC
Matthew B. Hoyt - Arden NC
Charles F. Helms - Asheville NC

Assignee:

BASF Corporation - Mt. Olive NJ

International Classification:

B01D 5700
B29C 4706

US Classification:

210739

Abstract:

A method of separating two immiscible, melt-viscosity-differing thermoplastic polymer components from a mixed liquid stream thereof forms two discrete and continuous phases having a sheath/core configuration, wherein the sheath substantially contains the polymer component with the higher melt viscosity and the core substantially contains the polymer component with the lower melt viscosity. The mixed liquid stream contains a predominant amount (i. e. , greater than 50% by volume) of the higher viscosity polymer component and a minority amount (i. e. , less than 50% by volume) of the lower viscosity polymer component. The method involves directing the stream through a shear zone at a shear temperature and a shear rate sufficient to form the two discrete and continuous phases, the first of which substantially contains the lower viscosity polymer component and the second of which substantially contains the higher viscosity polymer component.

US Patent:

59323469, Aug 3, 1999

Filed:

Jan 7, 1998

Appl. No.:

9/004032

Inventors:

Diane R. Kent - Arden NC
Matthew B. Hoyt - Arden NC
Charles F. Helms - Asheville NC

Assignee:

BASF Corporation - Mt. Olive NJ

International Classification:

D02G 300

US Classification:

428373

Abstract:

Multicomponent fibers and methods of producing the same are provided such that an inter-domain boundary layer is interposed between distinct domains formed of incompatible polymers so as to minimize (if not eliminate entirely) separation of the domains at their interfacial boundary. The polymer forming the inter-domain boundary layer therefore is provided so as to be compatible with the otherwise incompatible polymers forming each of the domains between which it is interposed.

US Patent:

58338934, Nov 10, 1998

Filed:

Mar 3, 1997

Appl. No.:

8/811061

Inventors:

Frank R. Jones - Asheville NC
Stanley A. McIntosh - Candler NC
Gary W. Shore - Asheville NC
Karl H. Buchanan - Arden NC
David B. Ledford - Arden NC
Wayne S. Stanko - Asheville NC
G. Daniel Gasperson - Candler NC
Charles F. Helms - Asheville NC

Assignee:

BASF Corporation - Mt. Olive NJ

International Classification:

D01F 104
D01F 110

US Classification:

264 13

Abstract:

Methods of continuously producing sequential lengths of different additive-containing melt-spun filaments include continuously supplying a melt-spinnable polymeric host material to orifices of a spinneret and controllably dosing at least one dispersible additive concentrate system containing a pigment in a liquid nonaqueous polymeric carrier to the melt flow of polymeric host material upstream of the spinneret orifices. In such a manner, a first polymeric mixture of the dispersible additive concentrate system and the polymeric host material is obtained which achieves an additive attribute. During a first time interval, the first mixture is extruded through the spinneret orifices; and thereafter, during a second subsequent time interval, the dosing of the at least one dispersible additive is changed so as to form a second mixture having a second additive attribute different from the first additive attribute while continuously supplying the melt flow of polymeric host material to the spinneret orifices. The melt-spun filaments will thus have a first length corresponding to the first additive attribute of the first mixture and a second subsequent length corresponding to the second additive attribute of the second mixture. The methods and additives employed most preferably achieve Hunter Green Purge Values of between about 0.