Lecture 4
Manufacturing of man-made fiber
Man-made fibers are manufactured by spinning the polymer. There are three major types
of spinning process. They are-
1. Melt Spinning (It is used for polymers that can be melted easily.)
2. Dry Spinning (It involves dissolving the polymer into a solution that can be
evaporated.)
3. Wet Spinning (It is used when the solvent can’t be evaporated and must be removed by
chemical means.)
Melt Spinning:
Melt spinning uses heat to melt the polymer to a viscosity suitable for extrusion. This type of
spinning is used for polymers that are not decomposed or degraded by the temperatures
necessary for extrusion. This method is used by 70% of the fibers.
Spinning process:
In melt spinning, polymer is heated and it melts to form a liquid spinning solution or dope.
1. Chips of polymers are fed to a hopper which is heated.
2. The melted polymer is extruded at high pressure and constant rate through a spinneret
into a relatively cooler air stream that solidifies the filaments.
3. Finally, the filament yarn either is immediately wound onto bobbins or is further treated
for certain desired characteristics or end use.
Example: Melt spinning is used for the production of polyester, nylon, olefin, saran and glass
fibers.
Dry spinning:
This method of spinning is used in manufacturing of acetate yarns. Dry spinning is used for
polymers that need to be dissolved in a solvent. Solvent spinning (dry spinning and wet
spinning) are used by 30% of the fibers.
Spinning process:
1. In dry spinning, a volatile solvent is used to dissolve the raw materials and form a
salutation..
2. The process involves the extrusion of the suitable liquid solution through the spinneret
into an air chamber.
3. The air reacts with the extruded streams causing them to solidify twisted and/or
processed further and then wound onto spools.
4. Finally the filament yarn either is immediately wound onto bobbins or is further treated
for certain desired characteristics or end use.
Example: Dry spinning is used in the production of acetate, triacetate, and some acrylic,
modacrylic, spandex, and PVC, PVA fibers.
Wet Spinning:
This method of spinning is more suitable for rayon fibers. This is the oldest, most complex and
also the most expensive method of man-made yarn manufacture. This type of spinning is
applied to polymers which do not melt and dissolve only in non-volatile or thermal unstable
solvents.
Spinning process:
1. In wet spinning, a non-volatile solvent is used to convert the raw material into a
solution.
2. Spinning involves the extrusion of an liquid solution through the spinneret in a chemical
bath that coagulates the solution into filament strands.
3. After extrusion, the solvent is removed in a liquid coagulation medium
4. Finally, the filament yarn either is immediately wound onto bobbins or is further treated
for certain desired characteristics or end use.
Example: Wet spinning is used in the production of aramid, Lyocell, viscose rayon, spandex,
acrylic and modacrylic fibers.
Difference between Melt spinning, Dry spinning & Wet spinning
Polyester
Trade Name :
Trade Name Country
Dacron USA
Terylene UK
Fortrel USA
Tetron Japan
Types of Polyester fibres :
Based on chemical structures, Polyester fibres divided into following types,
1. Polyethylene Terephthalate (PET) fibres
2. Poly-1, 4- Cyclohexylene – Dimethylene Terephthalate fibres(PCDT polyester fibres
3. Othes types of polyester fibres
PET polyester:
PET is made by the condensation of Terephthalic acid or a derivative such as dimethyl
terephthalate with ethylene glycol.
Physical properties:
Tenacity : dry 3.5 - 7.0 : wet 3.5 - 7.0
Elongation at break : dry 15 - 45 : wet 15 45%
Elastic Recovery : at 2% extension elastic recovery is 98 and at 5%
extension elastic recovery. 65
Melting point : 260 - 270 degree C
Hygroscopic nature:
o Polyester filaments and staple fibre are hydrophobic. The lack of polarity and the
extremely crystalline structure of polyester polymers resist the entry of water molecules
into the polymer system. MR% - 0-0.4%.
Chemical properties:
1. Effect of acid:
This resistance is further enhanced by the extreme crystallinity of the polyester polymer system which
prevents the entry of any acid and water molecules into the filament of staple fibre.
2. Effect of alkali:
The extreme crystallinity of the polyester polymer restricts the hydrolysis to the surface of the polyester
filament or staple fibre.
3. Effect of bleaches:
Normally polyester textile mtls do not need to be bleached.
4. Sunlight:
The benzene rings of the polyester polymer provide stability to the whole polymer, enabling the
polymers to withstand the detrimental effect of the sun’s ultra violet radiation.
5. Dye ability:
It is very difficult for dye molecules to penetrate the extremely crystalline polymer system of polyester
fibres. Only the relatibely small molecules of disperse dyes are used to dye or print polyester fibres.
6. Biological agents:
Resistance to moths, mildews, fungus
7. Solvents:
Resistant to all dry cleaning solvents.
[Link]: It will shrink from the flame and burn slowly giving off black smoke. Has a
somewhat sweet chemical odor. The residue is initially a hard cream-colored bead that becomes
darker tan.
Nylon
Viscose Rayon
Physical Properties
Property Value
Appearance Highly lustrous
Cross Section Serrated
Dry 18-23 cN/tex
Tenacity Wet 9.0-13.2cN/tex
17-25% of its original length
Dry before breaking
Elongation
23-32% of its original length
Wet before breaking
Initial Modulus 477cN/tex
Density 1.53 gm/cm3
Moisture Content 11-13% at 65 % RH
B. Chemical Properties
1. Action of Acid
Similar to cotton, viscose rayon is attacked by hot dilute or cold concentrated
mineral acids, which weaken and disintegrate the fibre.
Acids like sulphuric acid, hydrochloric acid etc. break down the cellulose
macromolecules of viscose rayon and produce hydrocellulose.
2. Action of Alkali
Like cotton, has high degree of resistance to the dilute alkalies. Strong solutions of
alkali cause swelling, with loss of the tensile strength.
3. Solvents
Viscose fibre dissolves in cuprammonium hydroxide solution.
4. Dye affinity: Good. Easily dyed by direct dyes, azoic dyes, vat dyes.
C. Thermal Properties
1. Effect of Temperature
Rayon is not thermoplastic, and does not melt on heating. It begins to lose strength at
150oC. after prolonged heating, it begins to decompose at 185-205 oC
2. Flammability
Rayon burns readily with a characteristic odor of burnt paper.
3. Effect of Sunlight
Oxide Viscose rayon withstands exposure to sunlight without discoloration; prolonged
exposure causes a gradual loss of tensile strength. This more sever if the fibre contains
titanium.
D. Micro-organisms
Mildews do not readily attack the cellulose of the fibre itself, but will feed on the size
that is left on the fibres after processing. Mildews will cause discoloration and weaken
the fibre if the attack is severe.
E. Electrical properties
The high moisture absorption of rayon tends to detract from its value for insulation
purpose. Under ordinary conditions, viscose does not develop static charges but
antistatic agents are added if the relative humidity is less than about 30%.