Controlling of threadline dynamics via a novel method to develop ultra‐high performance polypropylene filaments

A detailed study was conducted to investigate the effects of horizontal isothermal bath (hIB) on the production of ultra‐high performance polypropylene filaments. Two different commercial PP polymers were used with the melt flow rate of 4.1 and 36 g/10 min. The optimum process conditions depended on polymer molecular weight. Fibers showed distinct precursor morphology for each at each optimum process condition. However, two sets of filaments demonstrated similar fiber tenacity and modulus of about 7 and 75 g d^?1, respectively, for as‐spun and more than 12 g d^?1 for tenacity and more than 190 g d^?1 for modulus values of drawn fibers after just 1.49 draw ratio. The mean value for the modulus after the drawing process for the high melt flow rate was 196 g d^?1. The theoretical modulus of PP is 35–42 GPa¹⁹, (275–330 g d^?1), shows the hIB fiber's modulus performance is approaching its theoretical maximum value. Fibers had greatly improved thermal properties, degree of crystallinity, crystalline and amorphous orientation factors. The hIB spinning system produced highly oriented and predominantly amorphous structure for as‐spun fibers and a well‐defined, highly oriented crystalline fibrillar and amorphous structure after drawing process with the draw ratios lower than 1.5. POLYM. ENG. SCI., 55:327–339, 2015. © 2014 Society of Plastics Engineers     

Solid‐state polymerization of melt‐spun poly(ethylene terephthalate) fibers and their tensile properties

The production of high modulus and high strength poly(ethylene terephthalate) fibers was examined by using commercially available melt‐spun fibers with normal molecular weight (intrinsic viscosity = 0.6 dL/g). First, molecular weight of as‐spun fibers was increased up to 2.20 dL/g by a solid‐state polymerization, keeping the original shape of as‐spun fibers. Second, the polymerized as‐spun fibers were drawn by a conventional tensile drawing. The achieved tensile modulus and strength of as‐drawn fibers (without heat setting) were 20.0 and 1.1 GPa, respectively. A heat setting was carried out for the as‐drawn fibers. Tensile properties of the treated fibers were greatly affected by the condition of the heat setting. This was related to the increase of sample crystallinity and molecular degradation during the treatments. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 1791–1797, 2007     

Molecular structures and physical properties of heat‐drawn conjugate fibers

As‐spun poly(trimethylene terephthalate) (PTT)/poly(ethylene terephthalate) (PET) side‐by‐side conjugate fibers were drawn to investigate the effects of drawing conditions on structure development and physical properties. Effects of draw ratio and heat‐set temperature were observed. In the state of an as‐spun fiber, the molecular orientation of PTT was higher than PET, whereas PET molecular orientation increased remarkably over PTT with increasing draw ratio. Crimp contraction increased sharply at a draw ratio over 2.0, where the crystalline structure of the PET developed sufficiently. A heat‐set temperature of at least 140°C was required to develop sufficient crimp contraction. The crystallinity and orientation of the PET were attributed mainly to the crimp contraction of the drawn fiber. POLYM. ENG. SCI., 2011. © 2010 Society of Plastics Engineers     

Structure and properties of melt‐spun PET/MWCNT nanocomposite fibers

Polyethylene terephthalate (PET) melt‐spun fibers were modified with multiwall carbon nanotubes (MWCNT) to obtain conductive microfibers smaller than 90 μm in diameter. Physical properties such as crystallinity and orientation of as‐spun fibers were studied by X‐ray diffraction, Raman spectroscopy, and microscopy techniques at different draw ratios (DR) and MWCNT concentrations. Morphological and orientation analysis of MWCNT after melt‐spinning process showed agglomerates formation and highly oriented CNTs. The study of the orientation of PET crystalline phase in drawn fibers proved that the addition of nanoparticles decreases the orientation of crystalline units inside the fibers. The orientation of MWCNT as well as that of PET chains was studied using Raman spectroscopy at different DR and a high degree of CNT orientation was observed under high DR conditions. Mechanical and electrical properties of as‐spun fibers were also investigated. Our results showed that it was possible to achieve conductive fibers at a MWCNT concentration of 2% w/w, and more conductive fibers using higher DR were also obtained without increasing the MWCNT concentration. Mechanical properties results showed interestingly high value of maximum tensile strain at break (ε_max) of nanocomposite fibers, up to three times more than pure PET fibers. POLYM. ENG. SCI., 50:1956–1968, 2010. © 2010 Society of Plastics Engineers     

Structure development of poly(L‐lactic acid) fibers processed at various spinning conditions

Poly(L ‐lactic acid) (PLA) filaments were spun by melt‐spinning at 500 and 1850 mm^?1, and further drawn and heat‐set to modify the morphology of these PLA filaments. PLA yarns were characterized by wide‐angle X‐ray diffraction (WAXD) and sonic method. WAXD reveals that PLA yarns spun at 500 mm^?1 are almost amorphous while the PLA filaments spun at 1850 mm^?1 have about 6% crystallinity. This is different from PET filaments spun at the same speed that have almost no crystallinity. Both drawn‐ and heat‐set PLA filaments showed much higher crystallinity (60%) than do as‐spun fibers produced at 500 and 1850 mm^?1 speed, which is also higher than the usual heat‐set PET yarns. It appears that crystalline orientation rapidly reaches a value in the order of 0.95 at 1850 mm^?1 and that drawn‐ and heat‐set yarns have almost the same crystalline orientation values. Molecular orientation is relatively low for as‐spun PLA yarn, and molecular orientation increased to ～0.5 after drawing or heat–setting or both. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 1210–1216, 2006     

Spinning and properties of poly(ethylene terephthalate)/organomontmorillonite nanocomposite fibers

By in situ polycondensation, a intercalated poly(ethylene terephthalate)/organomontmorillonite nanocomposite was prepared after montmorillonite (MMT) had been treated with a water‐soluble polymer. This nanocomposite was produced to fibers through melt spinning. The resulting nanocomposite fibers were characterized by X‐ray diffraction (XRD), differential scanning calorimeter (DSC), and transmission electron microscopy (TEM). The interlayer distance of MMT dispersed in the nanocomposite fibers was further enlarged because of strong shear stress during processing of melt spinning. This was confirmed by XRD test and TEM images. DSC test results showed that incorporation of MMT accelerated the crystallization of poly(ethylene terephthalate) (PET), but the crystallinity of the drawn fibers just had a little increasing compared with that of neat PET drawn fibers. Also compared with pure PET drawn fibers, tensile strength at 5% elongation and thermal stability of the nanocomposite fibers were improved. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 95: 1443–1447, 2005     

Drawing in high pressure CO2—a new route to high performance fibers in memory of late Roger Porter

In this paper, we introduce a new draw technique for polymer orientation and apply it to different polymer fibers: poly(ethylene terephthalate) or PET, nylon 6,6, and ultra‐high molecular polyethylene (UHMWPE). In this technique, a polymer is drawn uniaxially in supercritical CO₂ using a custom high‐pressure apparatus. This technique can be used in replacement of a traditional drawing process or as a post‐treatment process. With PET, the technique is not effective at temperatures at or below 130°. In contrast, the process is highly effective for nylon 6,6 where CO₂ drawn fibers show significantly higher crystallinity and orientation along with improved mechanical properties. While the fibers are plasticized, the drawability of the fibers is only slightly dependent on temperature. High pressure CO₂ drawing of ultrahigh molecular weight polyethylene (UHMWPE) fibers is equally effective. Commercial high performance fibers can be drawn up to a ratio of 1.9 in asecond stage, resulting in large increases in tensile modulus and small improvements in tensile strength.     

In situ modulus enhancement of polypropylene monofilament through blending with a liquid‐crystalline copolyester

An immiscible blend of poly(propylene) (PP) with a thermotropic liquid‐crystalline polymer (TLCP, trade name Rodrun LC5000), a copolyester of 80/20 mol ratio of p‐hydroxy benzoic acid and polyethylene terephthalate was prepared in a twin‐screw extruder. The blend extrudate was fabricated as monofilament by using a single‐screw extruder equipped with a fiber line. The as‐spun filament was drawn at 120°C to enhance molecular orientation. Morphology, thermal, tensile, and dynamic mechanical properties of both as‐spun and drawn monofilaments were investigated. Almost continuously long TLCP fibers dispersed in PP matrix were obtained in the composite as‐spun monofilaments. The maximum modulus was found in 15 wt % TLCP/PP composite as‐spun filament, an increase of about 2.4 times that of the as‐spun neat PP. For the drawn filaments, the 10 wt % TLCP/PP composite showed a maximum modulus, an increase of about 1.5 times that of the drawn neat PP. The increase in the moduli was attributed not only to the reinforcement by TLCP fibrils with very high aspect ratio but also to the increases in PP crystallinity and molecular orientation through the drawing process. A remarkable improvement in the dynamic mechanical properties of the composite monofilaments was observed, especially in the high‐temperature region. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90:1337–1346, 2003     

Processing,structure, and properties of gel spun PAN and PAN/CNT fibers and gel spun PAN based carbon fibers

Polyacrylonitrile (PAN) and PAN/carbon nanotube (PAN/CNT) fibers were manufactured through dry‐jet wet spinning and gel spinning. Fiber coagulation occurred in a solvent‐free or solvent/nonsolvent coagulation bath mixture with temperatures ranging from ?50 to 25°C. The effect of fiber processing conditions was studied to understand their effect on the as‐spun fiber cross‐sectional shape, as well as the as‐spun fiber morphology. Increased coagulation bath temperature and a higher concentration of solvent in the coagulation bath medium resulted in more circular fibers and smoother fiber surface. as‐spun fibers were then drawn to investigate the relationship between as‐spun fiber processing conditions and the drawn precursor fiber structure and mechanical properties. PAN precursor fiber tows were then stabilized and carbonized in a continuous process for the manufacture of PAN based carbon fibers. Carbon fibers with tensile strengths as high as 5.8 GPa and tensile modulus as high as 375 GPa were produced. The highest strength PAN based carbon fibers were manufactured from as‐spun fibers with an irregular cross‐sectional shape produced using a ?50°C methanol coagulation bath, and exhibited a 61% increase in carbon fiber tensile strength as compared to the carbon fibers manufactured with a circular cross‐section. POLYM. ENG. SCI., 55:2603–2614, 2015. © 2015 Society of Plastics Engineers     

Effect of orientation and crystallinity on the photodegradation of poly(ethylene terephthalate) fibers

In this research, photodegradation of poly(ethylene terephthalate) (PET) fibers was investigated with emphasis on the morphological state of yarns. Two kinds of yarns, FDY (Fully Drawn Yarn) and POY (Partially Oriented Yarn), with different molecular orientation and crystallinity were applied in this research. FDY is spun in the same way as POY and subsequently drawn at high speed and then entangled before winding up. This sample has higher molecular orientation and crystallinity than the POY sample. Several analytical methods were applied in this study: viscometry, X‐ray diffraction, FTIR spectroscopy, UV–Visible spectrophotometry, and mechanical testing. Viscometry was used to determine molecular weight as a monitoring factor for degradation. X‐ray diagrams showed higher crystallinity for FDY samples during weathering process by irradiation. Results of mechanical testing indicated that the tenacity of the FDY fibers had less deterioration in comparison with the POY ones. POLYM. ENG. SCI., 2008. © 2008 Society of Plastics Engineers     

Melt spinning and drawing of 2‐methyl‐1,3‐propanediol‐substituted poly(ethylene terephthalate)

The structure and properties of fibers prepared from copolymers of poly(ethylene terephthalate) (PET) in which 2‐methyl‐1,3‐propanediol (MPDiol® Glycol is a registered trademark of Lyondell Chemical Company) at 4, 7, 10, and 25 mol% was substituted for ethylene glycol were studied and compared with those of PET homopolymer. Filaments were melt spun over a range of spinning conditions, and some filaments that were spun at relatively low spinning speeds were subjected to hot drawing. The filaments were characterized by measurements of birefringence, differential scanning calorimetry (DSC) crystallinity, melting point, glass transition temperature, wide‐angle X‐ray diffraction patterns, boiling water shrinkage, tenacity, and elongation to break. Filaments containing 25 mol% MPDiol did not crystallize in the spinline at any spinning speed investigated, whereas the other resins did crystallize in the spinline at high spinning speeds. However, compared with PET homopolymer, increasing substitution of MPDiol reduced the rate at which the crystallinity of the melt spun filaments increased with spinning speed and reduced the ultimate crystallinity that could be achieved by high‐speed spinning. The rate of development of molecular orientation, as measured by birefringence, also decreased somewhat with increasing MPDiol content. Shrinkage in boiling water decreased at high spinning speeds as the amount of crystallinity increased; however, the shrinkage decreased more slowly with increase in spinning speed as MPDiol content increased. Tenacity also decreased slightly at any given spinning speed as MPDiol content increased, but there was no significant effect on elongation to break. The addition of MPDiol in amounts up to 7 mol% increased the maximum take‐up velocity that could be achieved at a given mass throughput. This result indicates that the use of higher spinning speeds could potentially increase the productivity of melt spun yarns. Copolymer filaments spun at low speeds were readily drawn to produce highly oriented fibers with slightly less birefringence, crystallinity, and tenacity than similarly processed PET homopolymer. Preliminary dyeing experiments showed that the incorporation of MPDiol improved the dyeability of the filaments. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 2598–2606, 2003     

High tensile strength fiber of poly[(R)‐3‐hydroxybutyrate‐co‐(R)‐3‐hydroxyhexanoate] processed by two‐step drawing with intermediate annealing

High tensile strength fibers of poly[(R)‐3‐hydroxybutyrate‐co‐(R)‐3‐hydroxyhexanoate] [P(3HB‐co‐3HH)], a type of microbial polyesters, were processed by one‐step and two‐step cold‐drawn method with intermediate annealing. Thermal degradation behaviors were characterized by differential scanning calorimeter and gel permeation chromatography measurements. Thermal analyses were revealed that molecular weights decreased drastically within melting time at a few minute. One‐step cold‐drawn fiber with drawing ratio of 10 showed tensile strength of 281 MPa, while tensile strength of as‐spun fiber was 78 MPa. When two‐step drawing was applied for P(3HB‐co‐3HH) fibers, the tensile strength was led to 420 MPa. Furthermore, the optimization of intermediate annealing condition leads to enhance the tensile strength at 552 MPa of P(3HB‐co‐3HH) fiber. Wide‐angel X‐ray diffraction measurements of these fibers suggest that the fibers with high tensile strength include much amount of the planer‐zigzag conformation (β‐form) as molecular conformation together with 2₁ helix conformation (α‐form). © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41258.     

Direct drawing of gel fibers enabled by twist‐gel spinning process

A new twist‐gel spinning process for ultrahigh molecular weight polyethylene fibers is demonstrated which significantly increases the extraction rate of nonvolatile spin solvent while simultaneously reducing the consumption of extraction solvent by more than 75%. Applying twist to the gel fiber enables it to be directly hot‐drawn, allowing conventional solvent extraction to proceed significantly faster. While solvent extraction effectiveness is largely enhanced, the new process does not show reduced fiber properties. The tensile strength, Young's modulus, surface morphology, and geometry are relatively unaffected when compared to fibers produced using the conventional gel‐spinning process. The new twist‐gel spinning process is expected to improve the processing efficiency of gel‐spun high‐strength fibers, promoting broad expansion of these high performance fibers into applications that were previously prohibitive due to extremely slow production. POLYM. ENG. SCI., 55:1389–1395, 2015. © 2015 Society of Plastics Engineers     

A modified method for processing and characterization of organoclay‐based poly(ethylene terephthalate) nanocomposite fibers

In the current study, in order to prepare poly(ethylene terephthalate) (PET)/organoclay nanocomposite fibers, a slurry‐compounding method (SCM) was applied and compared to conventional melt‐compounding method (CMM) in terms of the dispersion of organoclays and the performance of the spun and or drawn fibers. The organoclays were synthesized by using three different alkyl phosphonium salts and compared with commercially available alkyl ammonium‐modified organoclays in terms of thermal stability and basal spacing. It was found that the alkyl phosphonium salts exhibited higher thermal stability and basal spacing with respect to commercial alkyl ammonium organoclays. Among them, tributylhexadecylphosphonium bromide resulted in superior properties; therefore, it was used to prepare the nanocomposite PET fibers. The organoclay content of 0.1–1 wt% was taken as the material parameter. It was demonstrated that the SCM yielded better dispersion of organoclays with respect to CMM. The drawn nanocomposite fibers prepared via SCM exhibited improved tensile strength and modulus in comparison to the neat‐PET. The maximum tensile properties for fibers were obtained at 0.5% organoclay loading in SCM. The thermal properties and the percentage of crystallinity were investigated by differential scanning calorimetry analysis. In addition, Fourier transform infrared spectroscopy was utilized to obtain the percentage of crystallinity of the fibers. POLYM. COMPOS., 34:887–896, 2013. © 2013 Society of Plastics Engineers     

Effect of melt spinning and cold drawing on structure and properties of poly (aryl ether ketone) (PAEK) fibers

The effects of melt spinning and cold drawing on structure development and resulting properties of poly (aryl ether ketone) (PAEK) have been investigated. Melt spun and subsequently cold drawn fibers were characterized by differential scanning calorimetry, wide angle X-ray diffraction, small angle X-ray diffraction, and birefringence techniques. At low take-up speeds, essentially amorphous fibers are produced. High take-up speeds result in development of crystallinity in the as-spun fibers. Cold drawing above the, T_g of PAEK causes further increase of crystallinity. Wide angle X-ray patterns indicate progressive alignment of chains along the fiber axis in as spun as well as in cold-drawn fibers with the draw down ratio and cold draw ratio. However, cold drawing was observed to broaden the WAXS peaks. SAXS patterns of cold drawn and fixed annealed fibers changed from two-point to four-point patterns indicating mosaic pattern formation of crystalline and amorphous regions. Mechanical properties including tensile strength, elongation at break, modulus, and yield strength were measured and correlated with fiber structure. Fracture surfaces of tensile tested fibers were observed using scanning electron microscopy and correlated with developed fiber structure.     

Characterization of poly(L‐lactic acid) fibers produced by melt spinning

Biodegradable poly(L ‐lactic acid) (PLLA) fibers were processed by a two‐step melt‐spinning method (melt extrusion and hot draw) from PLLA with three different viscosity‐average molecular weights (494,600, 304,700, and 262,800). Before spinning, the polymer flakes were first milled into powders and dried under vacuum. Viscosity‐average molecular weight of PLLA following the fabrication process was monitored. Tensile properties of as‐spun and hot‐drawn fibers were investigated. Morphology of the PLLA fibers was viewed under a scanning electron microscope. Crystallinity of these fibers was assessed by thermogram analysis of differential scanning calorimetry. Results showed that the extent of decrease in the viscosity‐average molecular weight of PLLA dropped sharply by 13.1–19.5% during pulverization and by 39.0–69.0% during melt‐extrusion. The hot‐draw process in this study had a little effect on the viscosity‐average molecular weight of PLLA. Smoother fibers could be obtained for the die temperature at least 230°C for raw materials with higher crystallinity (more than 75%) and at least 220°C for raw materials with lower crystallinity (about 60%). The as‐spun fibers showed crystallinity of 16.5–22.8% and the value increased to 50.3–63.7% after hot draw. Tensile moduli of the as‐spun fibers were in the range of 1.2–2.4 GPa, which were raised to 3.6–5.4 GPa after hot draw. The final PLLA fibers with 110–160 μm diameters showed tensile strengths of 300–600 MPa. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 251–260, 2001     

Effect of copolymer mixing on elongation property of as‐spun PET fibers

The change of elongation property in the melt spinning process of polyethylene terephthalate (PET) fibers, mixed with small amount of additive copolymer less than 5% by weight, was studied. The additive polymer was synthesized to improve the extensibility of matrix PET in the spinning process. The amount, molecular weight of additive polymer, and spinning conditions were changed to investigate the extensibility of as‐spun fibers. Experimental results show that the blend of copolymer improves the extensibility of as‐spun PET fibers. The elongation at break of as‐spun fibers increases with molecular weight and amount of additive polymer. The additive polymer prevents the fiber orientation and this causes the increase of extensibility of as‐spun fibers. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 1426–1431, 2006     

Two‐stage drawing process to prepare high‐strength and porous ultrahigh‐molecular‐weight polyethylene fibers: Cold drawing and hot drawing

High‐strength and porous ultrahigh‐molecular‐weight polyethylene (UHMWPE) fibers have been prepared through a two‐stage drawing process. Combined with tensile testing, scanning electron microscopy, and small‐angle X‐ray scattering, the mechanical properties, porosity, and microstructural evolution of the UHMWPE fibers were investigated. The first‐stage cold drawing of the gel‐spun fibers and subsequent extraction process produced fibers with oriented lamellae stacks on the surface and plentiful voids inside but with poor mechanical properties. The second‐stage hot drawing of the extracted fibers significantly improved the mechanical properties of the porous fibers because of the formation of lamellar backbone networks on the surface and microfibrillar networks interwoven inside to support the voids. With various processing conditions, the optimized mechanical properties and porosity of the prepared UHMWPE fibers were obtained a tensile strength of 1.31 GPa, a modulus of 10.1 GPa, and a porosity of 35%. In addition, a molecular schematic diagram is proposed to describe structural development under two‐stage drawing, including void formation and lamellar evolution. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42823.     

Crystallized polyarylene ether nitrile blends with improved thermal,mechanical, dielectric properties,and processability

In this work, the biphenol polyarylether nitrile (BP‐PEN) films with improved processability were prepared by blending low molecular weight (LMW) with high molecular weight (HMW) of BP‐PEN. The hybrid membrane exhibited excellent thermal stability and mechanical strength. The T_id values of the films were as high as 505°C–522°C. Melting behavior studies indicated that the crystallinity of LMW BP‐PEN was higher than that of HMW, which was confirmed by the X‐ray diffraction (XRD) patterns analysis as well. Scanning electron microscope (SEM) provided additional information on morphology and phase adhesion. Additionally, the polymer crystallinity dependent on dielectric properties of blends films is reported. Most importantly, it is found that the combination of LMW and HMW BP‐PEN would be an effective method to simultaneously increase the mechanical, thermal, dielectric properties, and polymer processability. POLYM. COMPOS., 38:126–131, 2017. © 2015 Society of Plastics Engineers     

High‐performance filaments by melt spinning low viscosity nylon 6 using horizontal isothermal bath process

Several techniques and treatments have been developed for the production of high‐performance nylon‐6 fibers. The inherent problems of low productivity, high production cost, and high energy consumption, complexity of chemical reaction, mass transfer, and waste recovery systems make most of them inappropriate for industrial application. Horizontal isothermal bath (hIB) is an alternative ecofriendly simple treatment that can be used during melt spinning process for production of technical textile fibers. The efficacy of hIB in improving the mechanical properties of multifilament nylon‐6 yarn is studied in this research. The results showed that such treatment can increase the molecular orientation of the amorphous and crystalline functions up to 0.54 and 0.983, respectively, and raised both the amorphous isotropy and fiber birefringence by 67 and 45%, respectively. Hot drawing of the yarn at a very low draw ratio of 1.38, increased the tenacity and modulus up to 10 and 43.9 g/den, respectively, and decreased the elongation to 27%. POLYM. ENG. SCI., 55:2457–2464, 2015. © 2015 Society of Plastics Engineers