Fibre and Filament Production

Spinning
• Spinning: The process of extruding a polymer
melt or solution through a spinneret.
• Spinneret: A die with multiple small holes
through which dope/melt is forced
• Spinning solution (dope, melt): Material
from which fiber is formed.
• Extrusion: Forcing dope or melt through tiny
holes in the spinneret.
• Melt spinning
Melt spinning (cont’d)
Dry spinning
Similar to melt spinning, but
starting polymer is in solution
and the solvent is removed by
evaporation (using hot air).
– First step is extrusion through a
spinneret
– Extrudate is pulled through a
heated chamber which removes the
solvent, leaving the polymer
– Used to produce filements of
cellulose acetates and acrylics.
 Wet spinning
• The polymer is in solution (just like in
dry spinning), but the solvent is non-
volatile. spinneret

• To separate polymer, the extrudate is

solution

passed through a chemical (e.g.

calcium & sodium salts, ethanol, etc.)
that coagulates/or precipitates the
polymer into coherent strands which coagulant
bath

are then collected on bobbins.

• Used for polymers that are not readily g
e
melted, e.g rayon (regenerated l

cellulose)
Wet spinning
Subsequent Processes
• Filaments produced by any of the three processes are
usually subjected to further cold drawing to align
crystal structure along the direction of filament axis
– Extensions of 2 to 8 are typical
– Effect is to significantly increase the tensile strength
– Drawing is accomplished by pulling filament between two
spools, where winding spool is driven at a faster speed than
unwinding spool.
• Washing
• Fabric finishing &
• Drying
 Polymer Additives
• Substances that change polymer properties and render
them more adaptable & versatile.
• Additives should have the following features: They
should:
– Be efficient in their function.
– Be stable under processing conditions
– Be stable under service conditions.
– Not bleed or bloom.
– Be non-toxic and not impart taste or ordour.
– Be affordable.
– Not adversely affect the properties of the polymer.
Bleeding & Blooming
• Bleeding
• Bleeding of additive into an adjacent material
occurs when the additive has a degree of
solubility in the polymer into which it is
incorporated and also soluble in the adjacent
material which could be a liquid or solid.
– Such bleeding may colour or contaminate the
adjacent material.
Bleeding & Blooming (cont’d)
• Blooming
• Occurs when an additive has totally dissolved
in the polymer at the processing temperature
but only partially soluble at the ambient
temperature.
– As a result, some of the additive is thrown out of
the solution on cooling & may collect on the
surface of the polymer mass.
Classes of Additives
– Delustering Agent: Titanium dioxide reduces luster;
produces dull, not bright fibers.
– Colourants: dyes and paints
– Whiteners or brighteners: Resist yellowing.
– Flame Retardants: Incorporate flame resistance to the
product, e.g. aluminium, chlorine, fluorine compounds.
– Antibacterial: Incorporate a compound that protects
from bacterial growth.
 Polymer Additives (cont’d)
– Blowing agents (gas producing substances): important in
foaming.
– Fillers: Added to a polymer to modify its mechanical
properties. e.g. carbon black.
– Stabilizers: Aimed at maintaining the molecular
archtecture of the polymer under the effect of heat, light,
etc.
– Impact modifiers: improve the impact resistance of the
product.
– Plasticizers: Improve on the flexibility to the polymer.
– Lubricants: Added to improve on the flow of the polymer
during the molding process.
– Antioxidants: Prevent oxidation during & after processing
Antifoaming Agents