Transient behavior of the planar-flow melt spinning process

Planar-flow melt spinning (PFMS) is a single-stage rapid manufacturing technique for producing thin metal sheets or ribbons. Commercial acceptance of PFMS requires ribbons to be cast with uniform thickness to tolerance. The process feeds molten metal through a nozzle onto a moving wheel where a puddle is formed and from which a continuous ribbon is ‘spun’. This study focuses on the time dependent behavior of the process. The dynamics of the process are modeled using unsteady mass balances, combined with a Bernoulli model of flow. Variations over a number of time scales are observed. The time scale over which the process can be treated as ‘quasi-steady’ is identified. Measuring the evolution of the puddle length and ribbon thickness within a cast indicates that the solidification rate also varies with time and a maximum in solidification rate is inferred.     

聚氨酯熔法纺丝工艺路线

封端法是用酚类或胺类化合物将聚氨酯中过量的二异氰酸酯基封闭起来 ,生成二异氰酸酯的再生体 ,在熔纺过程中 ,二异氰酸酯再生体受热分解 ,异氰酸酯基活化 ,产生以脲基甲酸酯基、缩二脲为主的交联体 ,提高产品的耐热性和弹性回复率。一步法主要是通过填加硅氧烷或聚碳酸酯来改善熔纺氨纶的性能。预聚体法是将聚氨酯切片熔融后 ,加入二异氰酸酯基过量的预聚体 ,与羟基过量的聚氨酯发生交联反应 ,修补断裂的软段 ,改善纤维的耐热性能和弹性回复率。     

熔体静电纺丝的工艺条件对纺丝纤维直径的影响

主要研究纺丝温度、纺丝电压、接收距离等参数对聚丙烯(PP)熔体静电纺丝纤维直径的影响。采用了只变一个参数,其它参数固定的常规实验方法。在实验条件范围内,随着纺丝温度的升高,纤维的平均直径逐渐减小,得到PP的最佳纺丝温度240℃。在固定电压的情况下,得到最佳接收距离7cm。在固定接收距离的情况下,随着电压的增加,电场中的喷射流熔体受到的电场力逐渐增大,得出最佳纺丝电压35kV。     

A similarity criterion of the optimal process in melt spinning

Experimental and simulation studies of optimization of the melt spinning process were carried out for nylon 6 fibers. The experiment and process simulation demonstrated that one criterion that can be applied in scaling up an optimized melt spinning process is to achieve the similar real time history of temperature and deformation rate in the spinway. Some aspects of the experiments and process simulation are discussed, together with the results of real time history analysis for a case of nylon 6 spinning.     

Heat transfer from moving fibers in melt spinning process

The purpose of this study is to develop a steady-state thermal model for melt spinning of polyester fiber by incorporating the radial heat conduction inside the fiber and the combined effect of radiation and convection at the boundary. The governing equations are obtained from the energy, mass, and momentum balances coupling with the rheological properties of the fibers. The effects of drag, surface tension, gravity, and inertia force are also taken into consideration in the analysis. The velocity profile, temperature profile, and the variation of cross-sectional area of the filament along the axial direction are solved by employing a finite-difference scheme.     

聚甲醛熔体纺丝的流变性能研究

采用Rheograph2002高压毛细管流变仪测定了聚甲醛(POM)的流变性能.结果表明:在所研究的温度和剪切速率(γ)范围内,POM熔体为假塑性非牛顿流体,其表观粘度(ηa)随温度和γ的提高均降低;POM的ηa对温度的依赖关系服从Andrade公式,粘流活化能随γ的提高而降低;在220℃以下,熔融时间对POM的ηa的...     

涤纶FDY熔融纺丝模拟研究

基于熔融纺丝动力学模型及理论,建立了涤纶全拉伸丝(FDY)熔融纺丝模型。在已知工艺参数条件下,模拟了丝条温度、速度、取向和结晶在纺程上的变化。结果表明:在纺程200,700,800,1 300,1 500 cm处,模拟值与实测值误差均小于10%,该模型可用于实际生产的模拟;根据模型,获得了热辊温度及速度对涤纶FDY的取向及结晶的定量关系;随着GR1速度降低和GR1温度提高,纤维的取向度和结晶度升高;随着GR2速度增加和GR2温度提高,纤维的取向度越大,结晶度越高。     

On-line measurement of orientation development in the high-speed melt spinning process

On-line measurement of birefringence was performed in the high-speed melt spinning process of poly(ethylene terephthalate) using an apparatus that incorporates a rotating polarizer for the measurement of the optical retardation of running filament. Particular attention was paid to the detailed measurements in the vicinity of neck-like deformation. Through the measurement at the take-up velocity of 5 km/min, development of birefringence under the strain rate up to about 1 ms^?1 was investigated. To analyze the relation between applied stress and birefringence, tension and temperature profiles of the spin-line were calculated based on the experimentally obtained diameter profiles. Even though the strain rate is extremely high, a linear relationship between birefringence and a parameter calculated by dividing stress by temperature was confirmed to hold up to birefringence and stress/temperature values of about 0.017 and 10 kPa/K, respectively.     

熔体直纺生产过程中的新型分散控制系统

介绍了由PC和PLC构成的新型分散控制系统,叙述了它在熔体输送控制系统的应用实例,给出了控制系统的硬件组成及软件实现方法。新型分散控制系统,使熔体输送的自动化水平有了很大的提高。能够自动、安全、稳定运行,同时也大大降低了施工和安装费用。     

二醋酸纤维素的增塑改性及熔融纺丝研究

采用聚乙二醇(PEG)作为增塑剂,对二醋酸纤维素(CDA)共混改性并进行熔融纺丝,研究了改性后的CDA及其纤维的结构与性能。结果表明:经PEG改性后,CDA的结构及晶型没有变化,CDA的熔点降低,由220℃降至190℃,而热失重5%时的温度仍然为300～310℃;改性后的CDA纤维的断裂强度随PEG含量增加而降低,断裂伸长率则随之提高,适宜的PEG质量分数为25%;PEG的加入增加了CDA可稳定熔融纺丝的温度区间,提高了CDA的可纺性。     

Effects of modified air quenches on the high-speed melt spinning process

A high molecular weight polyethylene terephthalate was spun into fibers in the speed range from 3,000–7,000 mpm. The effect of modifying threadline dynamics through a combination of enhanced and/or retarding air quenches on the resulting spinning performance, fiber structure, and mechanical properties was examined. Particular combinations of these threadline temperature profile modifications were shown to result in significant improvements in spinning performance and as-spun fiber structure. Extensive characterization of select fiber samples revealed higher orientation and crystallinity, larger crystal dimensions, and greater mechanical properties. These results also demonstrated the ability to provide continued improvement in fiber properties at very high take-up speeds where typically a decline is observed. It is concluded that the threadline temperature profile can be altered in such a way as to significantly enhance the resulting spinning performance and fiber structure over a wide range of take-up speeds.     

UHMWPE/聚烯烃共混物的性能及其熔融纺丝研究

将超高相对分子质量聚乙烯(UHMWPE)与共混组分聚烯烃(PB)按一定质量比计量,并加入质量分数为0.3%的抗氧剂1010,在双螺杆挤出机上共混造粒,研究了PB的用量对UHMWPE/PB共混物熔点和流变性能的影响;采用实验室熔融纺丝装置对UHMWPE/PB共混物进行纺丝,拉伸得到UHMWPE/PB共混纤维,研究了共混纤维的形貌、结晶性能和力学性能。结果表明:在共混温度为230~290℃时,UHMWPE/PB共混物可实现宏观上均匀共混;共混物具有介于两共混组分熔点之间的单一熔点,共混物熔点随UHMWPE含量的提高而提高;共混物熔体属假塑性流体,270~320℃条件下,随UHMWPE含量的增加,UHMWPE/PB共混物结构黏度指数逐渐增加,黏流活化能逐渐减小,共混物的熔体黏度对温度不敏感;当UHMWPE/PB质量比为1∶1,纺丝温度为310℃时,共混物具有良好的可纺性,经过19倍的后拉伸,所获得的UHMWPE/PB共混纤维直径为45μm,断裂强度可达16.4 c N/dtex,初始模量约190.0 c N/dtex。     

Studies on melt spinning process of hollow polyethylene terephthalate fibers

Dimensional change and profile development in the melt spinning process of polyethylene terephthalate hollow fibers were studied through the numerical simulations and experimental results. The simulation predicts the final dimensions and profiles development of the hollow fibers at various positions from the die. Experimental results show that the melt extruded from the spinneret coalesces initially to form a hollow inner core and the cross‐sectional shape holds for over the whole spinline with only variation in the hollow portion. Analysis of the effect of spinning parameters on hollow portion shows that the spinning temperature, mass throughput rate, and take‐up speed are the most critical variables in controlling the hollow portion followed by quench air velocity. The quench air temperature has relatively less effect than the other variables. As the mass throughput rate and quench air velocity increase and the take‐up speed and spinning temperature decrease, the hollow portion increases. To investigate the effect of die geometry, die having a different ratio of inner to outer diameter was used. The effect of change of process variables decreases as the die gap becomes narrow. POLYM. ENG. SCI. 46:609–616, 2006. © 2006 Society of Plastics Engineers     

The effect of melt spinning process parameters on the spinnability of polyetheretherketone

This study has been carried out to investigate the processing parameters affecting polyetheretherketone's (PEEK) spinnability in a melt spinning process. PEEK has excellent mechanical and thermal properties and fibers made from it could be used in extreme environments. Different PEEK grades were characterized thermally and rheologically to see which one is the most suitable for fiber spinning. The spinning tests made with the most suitable grade (Victrex 151G) show that increased processing temperature, increased capillary diameter or shorter spinning path length improves spinnability. The best fibers made in optimal processing conditions (400°C temperature, 30/1 mm capillary, and 5 cm spinning path) were 18 μm in average diameter. Because of the limitations of the system used, variations in fiber thickness were noticeable and worsened the spinning stability. Scanning electron microscope photos confirmed these variations, and they were also visible in an optical microscope. The selected low‐viscosity PEEK grade provided good spinnability but gave filaments with only mediocre mechanical properties, the tensile strength being around 280 MPa. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

熔体直纺PET-FDY工艺影响因素的研究

探讨了熔体黏度、端羧基值、熔体输送温度、压力降、停留时间、纺丝温度、吹风冷却及拉伸工艺对熔体直纺PET-FDY生产工艺的影响。     

Crystallization in polymer melt spinning

The crystallization behavior of poly(ethylene) terephthalate (PET) melt spun into fiber monofilaments was examined using a laboratory set-up. The wind-up speeds ranged from free fall under gravity to 1500 m/min. The major additional variables that were manipulated included the mass flow rate and the filament temperature profile. The structure of the as-spun fibers was probed using tensile tests, differential scanning calorimetry, optical birefringence, and x-ray diffraction. It was found that while the filaments that had been spun nonisothermally were essentially amorphous, those that had been made under isothermal conditions at temperatures ranging from 180°C to 240°C were oriented and crystalline. In addition, the rate of oriented crystallization was much greater than that under quiescent conditions at the same temperature. This is perhaps the first published study which shows that highly crystalline (up to 40% crystallinity) PET fibers can be obtained at low spinning speeds merely by altering the fiber temperature profile while the material is still above the polymer glass transition temperature.     

Dynamics of the threadline in melt spinning

In the nylon 6 melt spinning process at speeds of 900 and 1200 m/min the quenching is done in a stepwise manner. The effect on physical data of the drawn yarn is investigated and correlation between quench height, water takeup, and boiloff shrinkage discussed. Length changes across the takeup machine are also measured as function of quench height and seem to correlate with physical data. The speed of length changes for both finished and unfinished yarn as a function of quench height suggests a molecular oscillation along the spinning line rather than a continuous orientation of the molecular structures. A secondary disorientation zone is defined.     

涤纶工业丝熔体直纺生产技术的研发

采用液相增黏聚酯熔体,开发了200 kt/a涤纶工业丝熔体直纺生产技术,探讨了高黏熔体输送和大容量多头重旦纺丝等工艺,并与固相缩聚切片纺进行了对比分析。结果表明:涤纶工业丝熔体直纺技术省去了冷却切粒、固相缩聚、熔融挤出等工序,工艺流程紧凑,提高了生产效率,比固相缩聚熔融纺丝设备投资减少44.3%,生产能耗下降32.46%;生产的各种规格的涤纶工业丝质量指标符合国家标准GB/T16604—2008。     

On the dynamics of melt spinning

The dynamics of melt spinning was examined in the case of a Lethersich liquid taking also into account a phenomenologic way as well the transition zone between shear and elongational flow. The shape of the fluid jet was measured under many spinning conditions; the filament temperature and the fluid viscosity were then calculated. The experimental viscosity temperature relationship was compared with the W. L. F. equation, and the comparison makes it clear that the Newtonian model is not adequate whereas all the experimental evidence is in qualitative accordiance with the proposed model.