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Lec Fiber Spinning

There are three main types of man-made fiber spinning processes: 1. Melt spinning extrudes molten polymer through spinnerets to form filaments, which are drawn and cooled. It is used for nylon, polyester, and polypropylene. 2. Dry spinning dissolves polymer in a volatile solvent, which is evaporated in a heated chamber after extrusion to form solid fiber. It requires heat-resistant polymers and solvents. 3. Wet spinning uses a solvent solution and coagulation bath, where the fiber solidifies upon contact. Viscose rayon and acrylic are made through wet spinning. Each process has advantages for certain polymers and applications.

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137 views28 pages

Lec Fiber Spinning

There are three main types of man-made fiber spinning processes: 1. Melt spinning extrudes molten polymer through spinnerets to form filaments, which are drawn and cooled. It is used for nylon, polyester, and polypropylene. 2. Dry spinning dissolves polymer in a volatile solvent, which is evaporated in a heated chamber after extrusion to form solid fiber. It requires heat-resistant polymers and solvents. 3. Wet spinning uses a solvent solution and coagulation bath, where the fiber solidifies upon contact. Viscose rayon and acrylic are made through wet spinning. Each process has advantages for certain polymers and applications.

Uploaded by

sonyheart
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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FIBER SPINNING

FORMS OF MAN MADE FIBERS


MMF are produced in three types –
1. Filament: Filament fibres are spun from spinnerets
with 350 holes or less is determined by the size of
the yarn to be made
Monofilament: This filament is made only of a
single filament.
Multifilament: These filaments are made of more
than one filament.
2. Staple: Staple fibre is of limited and relatively short
length
3. Filament tow. An assemble of twist free fibre.
MAN MADE FIBERS
 Man-made fibers are classified into three classes, those
made from natural polymers, those made from synthetic
polymers and those made from inorganic materials.
 Fibers from Natural Polymers:
 The most common natural polymer fiber is viscose, which
is made from the polymer cellulose obtained mostly from
farmed trees. Other cellulose-based fibers are Lyocell,
Modal, Acetate and Triacetate. Less common natural
polymer fibers are made from rubber, alginic acid and
regenerated protein.
MAN MADE FIBERS

 Fibers from Synthetic Polymers:


 There are many synthetic fibers i.e. organic fibers based on
petrochemicals. The most common are polyester, polyamide
(often called nylon), acrylic and modacrylic, polypropylene,
the segmented polyurethanes which are elastic fibers known
as elastanes (or spandex in the USA), and speciality high-
tenacity fibres such as the high performance aramids and
UHMwPE (Ultra High Molecular weight PolyEthylene).
MAN MADE FIBERS

 Fibers from Inorganic Materials:


The inorganic man-made fibers are fibers made from
materials such as glass, metal, carbon or ceramic. These
fibers are very often used to reinforce plastics to form
composites.

CARBON (CF)
GLASS (GF)
METAL (MTF)
BORON (BF)
SILICA (SiC)
SILICA CARBIDE (SiC)
CERAMIC (CER)
SPINNERETTE

 A nozzle or plate provided with fire holes or slits through a


fibre forming solution or melt is extruded in fibre
manufacturing is called spinneret. This is the most important
part of a MMF producing m/c. The number of holes, sizes
and shapes vary with the filament desired.
FEATURES OF
SPINNERETTE
SPINNERET:
Spinneret length: 10-25 mm
Spinneret diameter: 30-200 mm
Spinneret thickness: 3.0 mm
Hole dia: 0.1.-0.8 mm
Problems:
-Breaking (On account of high pressure and temp)
-Clogging (The holes can be blocked for solid particles mix with polymer solution).

Remedies:
-For breaking problem: the spinneret is to be
changed.
-For clogging: the spinneret should be cleaned after
some days.
Number of holes in spinneret:

1. For monofilament: 1-3

2. For multifilament: 100-1000

3. Filament tow: up to 50,000


SPINNING

 The conversion of polymer into fiber is called spinning. The fiber


forming substance is made temporarily fluid, extruded through
spinneret and then returned to solid state (by solidification) in fiber
form.
 Three types of spinning process:
 Melt spinning (Synthetic).

 Wet spinning.

 Dry spinning.
MELT SPINNING

 The process of spinning by which fiber or filament is produced from


melted polymer chips by extruding through spinneret continuous
filament produced here.
 Number of filament depends on number of holes in spinneret.
 It is the most critical operation in the production of nylon polyester,
and polyolefin, poly propylene fibers as number of fiber properties
such as uniformity, crystallinity, and orientation are imparted to the
yarn during processing.
REQUIREMENTS FOR MELT
SPINNING
 The polymer should not be volatile
 The polymer should not decompose in the molten state and the
melting point.
 Polymer should be 30 degree centigrade less than its
decomposition temp.
MELT SPINNING
.

Melt spinning is a specialized extrusion process that employs


a spinneret to form multiple continuous filaments which form
polymeric fibers after solidification. In this process the
polymeric melt is forced out through tiny holes of a device
called a spinneret in the form of high viscosity continuous
polymer filaments which are solidified by cooling/quenching.
While solidifying, these filaments are drawn, which causes
the molecular chains to preferentially align along the fiber
axis. This alignment promotes crystallization and significantly
increases the fiber strength. This is used in industry to
produce random fiber networks.
MELT SPINNING

Advantage:
 Can be used for both staple and continuous filament.
 Direct and simple process.
 No environment pollution.
 No solvent required.
 Non toxicity and no risk of explosion.
 High production speed (2500 – 3000 ft/min)
 Low investment cost.
 Disadvantage:
 Required more proper maintenance of the m/c.
 Heat of input is high.
MELT SPINNING
Typical melt spinning:
Polymer Melting point
Nylon – 6, 6 264oC
Nylon – 6 220oC
PET 264oC
Polypropylene 167oC
Poly ethylene 125oC
DRY SPINNING

 In dry spinning, the fiber forming polymer dissolved in a volatile


solvent is introduced into a heated drying chamber where the solvent
is evaporated and solid fiber is obtained through spinneret.

Required Properties of solvent:


Solvent should be volatile.
It should be organic.
It should have low boiling point.
It should be comparatively cheap.
It should be thermally stabilized.
It should be non toxic.
DRY SPINNING

 Dry spinning solvent:


Fibre Solvent
I) Cellulose -Acetone + (2-6) % water
II) II) Triacetate -Methylene chloride (40%)
+ Methanol (10%)
III) Poly acrylonitrile -Di-methyl formamide or
Dimethyl acetamide.
IV) Spandex - DMF, DMAC.
V) Modacrylic - Acetone.
Dry spinning Process
DRY SPINNING

 Advantage:
 Yarn does not require purification
 Suitable for producing fine denier yarns
 It is recommended process for heat sensitive polymers
 Lower solvent is required because of higher polymer
concentration in the dope.
 The dry spinning method is a relatively flexible one and spinning
conditions can be modified
 The post spinning operations are simple like that of melt
spinning.
DRY SPINNING

 Disadvantage:
 Investment cost is high.
 Toxic and risk of explosion.
 Heat input is very high.
 Can not be used for staple fibre production.
DRY SPINNING

 List of Fibers
 Cellulose acetate, cellulose triacetate, acrylic, modacrylic,
aromatic nylon, and polyvinyl chloride are made by dry
spinning
WET SPINNING:
 In wet spinning a suitable solvent is used to prepare fibre forming solution
and another coagulant is used in coagulating bath.
 Solution is extruded through spinneret and in contact of coagulant
cellulose is regenerated.
Table of typical Wet Spinning solvent and coagulant

Fiber Solvent Coagulant


Viscose Aqueous of sodium salt & Dilute H2SO4+Na2SO4+ZnSO4
xanthate ester

Acrylic Dimethyl-acetamide 50% aqueous Dimethyl-


(DMA) acetamide
PVA DMF (Dimethyle Formide), 30% aqueous DMF
Water
Spandex DMA 30% aqueous DMA
WET SPINNING
WET SPINNING

 Advantage:
 Suitable for staple fibre.
 Both organic and inorganic solvent can be used.
 Low temp reqd.
 Process can be continuous.
 Investment cost is low.
 Disadvantage:
 Slow spgn speed.
 Washing and bleaching of fibres are needed.
 Toxic.
SPINNING: DIFFERENCE

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