Effect of winding speed on the structure and properties of as‐spun poly(trimethylene 2,6‐naphthalenedicarboxylate) fibers as compared to poly(ethylene terephthalate) fibers

We present a comparative study of melt spinning of poly(trimethylene 2,6‐naphthalenedicarboxylate) (PTN) and poly(ethylene terephthalate) (PET) fibers with respect to the effect of winding speed (2000–6000 m/min): Structural changes were followed by X‐ray analysis, calorimetry, and measurements of density, boiling water shrinkage, and birefringence. As‐spun PTN fibers exhibited a low degree of crystallinity at relatively low speeds (< 2000 m/min). An increase in winding speed up to 6000 m/min only resulted in a minor enhancement of crystallinity and orientation. The small change of structural parameters accounted for the fact that tenacity and modulus did not rise significantly with increasing winding speed, contrary to the PET fibers. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 2489–2497, 2002     

Computer Simulation of Polyester High‐Speed Thermal Channel Spinning

A mathematical model to describe the thermal channel spinning (TCS) process in PET high‐speed melt‐spinning has been developed. This model, which is based on the spinning process kinematics, includes the effects of acceleration, gravity, and surfacial air friction. It incorporates the constitutive equation of PET polymer, the heat transfer related to the transverse air blowing and, in particular, to a convection and radiation combining procedure in the thermal channel, while taking into account the nonisothermal crystallization kinetics related to temperature and molecular orientation as well as the elongational viscosity of PET polymer connected with temperature, intrinsic viscosity and crystallinity. The developments of crystallinity, molecular orientation and morphological features of high‐speed‐spun PET fiber in the TCS process are investigated at take‐up speeds ranging from 3 600–4 400 m/min and thermal channel temperatures ranging from 160–200°C. The simulated results of this model are compared with the measured crystallinity, diameter, and birefringence of the spun yarn. The “necking point” in the TCS spinline can be predicted by this model.     

Modification of PET in high‐speed melt spinning by blending with PEN

Blends of polyethylene terephthalate (PET) and polyethylene naphthalate (PEN) were melt spun using a high‐speed winding process in a single‐screw extruder combined with a spinning setup. The filaments had a single T_m and T_g, which indicates excellent compatibility in both the amorphous and crystalline phases. Birefringence and wide angle X‐ray measurements indicated that compounding PEN into PET suppresses stress‐induced orientation and decreases the stressinduced crystallization in the filaments. Adding PEN to PET relaxes the formation of skin‐core structures for as‐spun fibers and reduces the occurrence of broken filaments. Although the addition of PEN reduced crystallinity, it did not affect the tenacity and the shrinkage of the compounded filaments. The elongation of the fibers could be reduced by 30% to 40%, eliminating the need for a further drawing. These results are attributed to PEN's rigid backbone. Adding PEN to PET improves PETs spinnability during high‐speed spinning.     

熔融纺丝成形条件对PET初生丝超分子结构及其力学性能的影响——第1报 不同纺速下PET初生丝超分子结构及其力学性能的研究

本文借助于沸水收缩率、自然拉伸比以及用X射线衍射法测定的结晶度,表观晶粒尺寸和晶区取向因子等指标来描述熔融纺丝时不同纺速下PET初生丝的超分子结构。纺丝速度在1500～4800m/min范围内变化。测得的数据表明在较低的纺速下卷取的PET初生丝是不结晶的,而在较高纺速下纺制的PET初生丝结晶度要高得多。在实验的纺速范围内,PET初生丝的结晶度在纺速增加的过程中有突变现象,这主要是分子取向诱导所致,也即存在一个诱导结晶的临界取向度。最后,就不同纺速下PET初生丝的力学性能特征值进行了讨论。     

Properties of high‐speed spun high molecular weight poly(ethylene terephthalate) filaments

High‐speed spinning of high molecular weight poly(ethylene terephthalate) (PET) having an intrinsic viscosity of 0.98 dL/g was performed at the take‐up velocity range of 2.5–5.5 km/min. The structure of the as‐spun filaments was analyzed by density, birefringence, WAXS, DSC, boiling water shrinkage, and tensile properties. Stress‐induced crystallization takes place above 3 km/min, which is confirmed by the steep increase in density, the growth of the crystal size, melting point increase, and the decrease in boiling water shrinkage. The plot of crystallinity versus birefringence shows that crystallinity increases drastically after birefringence reaches the value of about 0.075. A comparison with the data of other researchers will clearly present the effects of molecular weight on the properties of PET filaments spun at high speed, for example, the take‐up velocity range of the steep increase in density for high molecular weight PET is lower than that for low molecular weight PET by about 1 km/min. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 71: 1283–1291, 1999     

Structure development in melt‐spinning syndiotactic polystyrene and comparison to atactic polystyrene

Syndiotactic polystyrene (s‐PS) and atactic polystyrene (a‐PS) were melt‐spun into filaments. The s‐PS filaments exhibited increasing amounts of crystallinity and orientation with increasing drawdown ratio and spinline stress. The a‐PS filaments were amorphous but exhibited birefringence. The birefringence and Hermans orientation factors for a‐PS were proportional to this spinline stress. In ice water and at low drawdown ratios, the s‐PS is glassy or mesomorphic. At higher drawdown ratios and spinline stresses, it crystallized. The crystalline form was the zigzag TTTT hexagonal α‐form. The birefringence and orientation factors of the s‐PS filaments were higher than those of the a‐PS filaments and the difference of the birefringence increased with increasing spinline stress. Mechanical testing results showed that the Young's modulus and tensile strength generally increased with increasing spinline drawdown ratio for both a‐PS and s‐PS filaments. The elongation to break was enhanced for both materials by increased chain orientation. Polym. Eng. Sci. 44:2141–2147, 2004. © 2004 Society of Plastics Engineers.     

Development of high‐tenacity,high‐modulus poly(ethylene terephthalate) filaments via a next generation wet‐melt‐spinning process

In this study, PET (intrinsic viscosity of 1.05 dl/g) was melt processed with a horizontal isothermal bath (HIB) treatment. Tensile properties of PET fiber samples were highly increased by using the HIB. The process‐structure‐property relationship of control (no HIB) and HIB fiber samples were characterized by tensile testing, differential scanning calorimetry, birefringence measurement, scanning electron microscopy and hot‐air shrinkage measurements. It was found that HIB fiber samples, which had been subjected to post‐drawing process, had a high degree of molecular chain orientation, that is, a high birefringence, high crystallinity and a fibrillar structure. The best tensile property acquired from a HIB‐drawn PET fiber sample was 10.24 g/d in tenacity, 114.17 g/d in modulus, and 13.49% in elongation at break. Applying the HIB in the melt spinning process was simple and required only small process space; hence, it is cost effective. In addition, acquiring HIB fiber samples was successful at a final take‐up speed of 2,500 m/min. Hence, this HIB‐assisted melt spinning technology has a high potential to be used in industries for technical textiles applications. POLYM. ENG. SCI., 57:224–230, 2017. © 2016 Society of Plastics Engineers     

Cellulose fibers from cellulose/1‐ethyl‐3‐methylimidazolium acetate solution by wet spinning with increasing spinning speeds

Cellulose fibers from cellulose/1‐ethyl‐3‐methylimidazolium acetate solution were prepared by wet spinning with increasing extrusion speeds and draw ratios. The effects of spinning speeds on the structures and mechanical properties of these fibers were investigated by using scanning electron microscopy, wide angle X‐ray diffraction, birefringence, thermogravimetric analysis, tensile‐fineness tester, and wet friction. The results showed that the crystallinity, orientation, and mechanical properties of the fibers were improved with increasing draw ratio. The break draw ratios, degrees of crystallinity and orientation, tenacities, and wet friction time of the cellulose fibers decreased with increasing extruding speeds. The wet friction time decreased with increasing draw ratio and decreased faster under higher extrusion speed. Due to the high dope concentration and the increased draw ratio, the maximum tenacity of the regenerated cellulose fibers reached 2.73 cN/dtex. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40225.     

Effect of spinning speed on the structure and physical properties of filament yarns produced from used PET bottles

In the previous work (S. Kiantash, MS Thesis, Amirkabir University of Technology, Textile Engineering Department, Tehran, Iran, 2002), the possibility of producing filament yarns from used PET bottles was investigated and the production was successfully carried out. To improve physical properties and to have a detailed understanding of the molecular structure, spinning variables such as the take‐up speed (one of the most influencing factors) should be varied and studied. In the present work, continuous filament yarns from virgin PET chips and used PET bottles were produced at the two take‐up speeds of 2500 and 3000 m/min. Optical birefringence, crystallinity (obtained from three methods including density, calorimetry, and FTIR), tenacity, breaking elongation, initial modulus, and shrinkage of yarns were measured and compared. Optical birefringence and crystallinity (obtained from all three methods) of used samples show higher values compared with those of virgin samples produced at both take‐up speeds. Consequently, the tenacity of used samples is higher and breaking elongation is lower. Generally, samples having bigger crystallinity present higher initial modulus and smaller shrinkage. However, results of initial modulus and shrinkage do not correspond to this assumption. As it was predicted, increasing the take‐up speed resulted in an increase in the optical birefringence, crystallinity, tenacity, and initial modulus and a reduction in the breaking elongation of both virgin and used samples. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 3972–3975, 2007     

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     

Structure development in melt spinning filaments from polybutylene terephthalate based thermoplastic elastomers

Structure development in polybutylene terephthalate (PBT) and thermoplastic elastomers (TPEs) based on PBT during the melt spinning process was investigated. Melt spun filaments were examined using wide angle X‐ray diffraction and birefringence. Crystalline orientation was characterized in terms of Hermans‐Stein orientation factors. Crystalline orientation and birefringence were found to correlated with spinline stress better than drawdown ratio. Crystalline orientation development was strongly dependent on spinline stress. The TPEs with low PBT content had low birefringence although the crystalline orientation was often high.     

Spinline tension control in melt spinning by discrete adaptive sliding‐mode controllers

The spinline tension plays a critical role in the development of fiber structures and the quality of as‐spun yarns in melt spinning. Implementing a controller to adjust the spinline velocity is helpful to maintain the spinline tension at a target level with small fluctuation, enabling as‐spun yarns to possess the desired tenacity and uniform qualities. The spinline tension system is difficult to model and the stochastic disturbance always exists. The discrete adaptive sliding‐mode controller can robustly and adaptively deal with the system with the unknown model and stochastic disturbance, such as the spinline tension system. The algorithm estimates the parameters of the controller in the sense of minimizing the deviation from the sliding surface, thus reducing the variation of the tension response about the desired level. The sliding surface is defined by an asymptotically stable polynomial, and seven stable polynomials are chosen in experiments. The experiments are carried out by using a laboratory type of the melt spinning setup to produce polypropylene as‐spun yarns. Compared with the results without control, the proposed controller can not only maintain the mean of the tension response close to the target level but also reduce the standard deviation to the value, which is generally acceptable to the manufacturer. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 3816–3821, 2006     

Crystal structure and orientation behavior of transversely compressed poly(ethylene‐co‐1‐octene) filaments

A basic study on crystal structure and orientation behavior of transversely compressed ethylene‐1‐octene copolymer with different 1‐octene contents was described. All polymers were first melt spun under different spinline stress and subsequently transversely compressed. For the melt‐spun filaments, an orthorhombic crystal structure was found for all polymers, but a pseudo‐hexagonal mesophase was also found for polymers with the highest 1‐octene level (13.3 mol%). For the transversely compressed filaments, several reflection peaks from a monoclinic unit cell were found for polyethylene without octene. For those with higher octene levels, the reflection peaks from monoclinic became fainter and disappeared for the one with the highest 1‐octene level. After being transversely compressed, the (110) and (200) peaks of orthorhombic crystal structures became oriented along the meridian direction, which is the fiber axis direction. The reason for this appears to be that the compression deformation of the filament induces elongation along its width direction and shrinkage along its length and thickness direction, and in this change the polymer chain orients. POLYM. ENG. SCI., 2008. © 2008 Society of Plastics Engineers     

Melt spinning and annealing of poly(ethylene terephthalate)/p‐hydroxybenzoate liquid crystalline polymer

Poly(ethylene terephthalate)/p‐hydroxybenzoate (PET/PHB) copolymer materials have relatively low melt viscosity because of the 60 mol % PHB material having a value that is lower by approximately two orders of magnitude than the value for PET homopolymer. The structure development during melt spinning and thermal treatment (annealing) of liquid crystalline copolyesters, with a rigid backbone structure, were analyzed through the density, birefringence, X‐ray diffraction, DSC, dynamic viscoelasticity, and tensile testing. As the take‐up velocity increased, the birefringence of PET/PHB as‐spun fiber increased, which indicated that it directly influenced the initial modulus and specific stress. The lateral packing of PHB molecular chain in a copolymer was shown to be loosened in the course of thermal treatment. The thermal treatment slightly increased the crystal orientation factor, whereas total molecular orientation was decreased by annealing. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 94: 1265–1278, 2004     

Crystallization and orientation development in fiber and film processing of polypropylenes of varying stereoregular form and tacticity

We investigated the crystallization and orientation development in melt spinning and tubular blown film extrusion of several different types of polypropylenes, including conventional high tacticity isotactic polypropylenes (iPP) and metallocene catalyst low tacticity iPPs and syndiotactic polypropylenes (sPP). The fiber and film samples were characterized by wide‐angle X‐ray diffraction (WAXD), birefringence and differential scanning calorimetry (DSC). In melt spinning iPP, we found that the mesomorphic structure of iPP is more readily formed in lower tacticity fibers, and significant amounts of hexagonal β‐form crystals are found in low tacticity iPP fibers spun at high draw‐down ratios. Low tacticity iPP fibers exhibited a significant decrease in the crystalline chain‐axis orientation at high draw‐down ratios, resulting from increased epitaxially branched lamellae. Melt‐spun sPP fibers exhibit Form I helical structure at low spinning speeds and Form III zigzag all trans structure at high spinning speeds. We found that the level of spinline stress is the governing factor for this structural change. Melt‐spun sPP fibers exhibit much higher chain‐axis (c‐axis) orientation factors (f_c) and lower birefringence than iPP fibers spun at the same spinline stresses. In tubular blown sPP films, the a‐axis of Form I unit cell tends to orient perpendicular to the film surface, while the b‐axis of monoclinic α unit cell does so in iPP blown films.     

热管纺丝工艺的模型研究

利用ＰＥＴ聚合物的本构方程，与热管和侧向冷却风有关的热传递机理以及纺丝运动学和非等温结晶动力学等建立了热管纺丝过程的数学模型。运用该数学模型进行了模拟计算，并得到了ＰＥＴ纤维热管纺丝线上的纺丝线张力、运行速度、温度、双折射、结晶度和直径沿纺程的梯度分布。于不同的工艺条件下在德国Ｂａｒｍａｇ公司生产的热管纺丝设备上纺制了ＴＣＳ－ＰＥＴ纤维，并分别测定了其卷绕丝的直径、双折射和结晶度。模拟计算得到的卷绕丝的双折射、结晶度和直径与实测结果吻合良好。     

Melt spinning of metallocene catalyzed polypropylenes. II. As‐spun filament structure and properties

The melt spinning of metallocene catalyzed isotactic polypropylene (miPP) resins was investigated. The as‐spun filament properties from six miPP resins were studied with melt flow rates (MFR) between 10 and 100, and a Ziegler–Natta catalyzed isotactic polypropylene (zniPP) resin with a MFR of 35 was studied for a comparison. Generally, as the molecular weight increased the filament density increased, the birefringence decreased, the tensile strength decreased, and the elongation to break increased. As the spinning speed increased, the density, birefringence, tensile strength, and crystalline and noncrystalline orientation functions generally increased. However, the low MFR miPP and the zniPP resin had decreases in the birefringence and tensile strength with an increase of the spinning speed. The miPP resins were found to have breaking tensile strengths up to 50% higher than the zniPP resin at similar spinning speeds. The observed fiber properties were explained based on the nature and orientation of noncrystalline portions of the fibers. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 3237–3247, 2001     

Process–structure–property relationship of melt spun poly(lactic acid) fibers produced in the spunbond process

We report on the process–structure–property relationships for Poly(lactic acid) (PLA) filaments produced through the spunbond process. The influence of spinning speed, polymer throughput, and draw ratio on crystallinity and birefringence of fibers were evaluated. We established that increasing spinning speed increases crystallinity and birefringence of fibers. We also investigate the role of fiber structures on fiber tensile properties—breaking tensile strength, strain at break, initial modulus, and natural draw ratio. An increase in spinning speed leads to a higher breaking tensile strength, higher initial modulus and lower strain at break. We have shown an almost linear relationship between breaking tensile strength of PLA fibers and birefringence. This indicates that improved tensile properties at high spinning speeds can be attributed to enhanced molecular orientation. The dependency of fiber breaking tensile strength and strain at break on spun orientation were explained with natural draw ratio, as a measure of spun orientation. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 44225.     

Structure development in melt spinning of poly(ethylene‐co‐octene) filaments with various comonomer contents

An experimental study of the spinnability and the variation in crystallinity and orientation of melt spinning of poly(ethylene‐co‐octene) with different contents of comonomers was carried out. The spinning behavior of these polymers was investigated under different draw‐down ratios and temperatures and correlated to spinline stress. The melt‐spun filaments were characterized by wide‐angle X‐ray diffraction birefringence, and differential scanning calorimetry. S‐1 is a high‐density polyethylene and S‐2, S‐3, and S‐4 have 16, 22, and 38 wt % octene. An orthorhombic unit cell was found in all four polymers, but a dominant hexagonal structure (perhaps mesophase) was found for the highest octene level (S‐4). The orientation factors for the a‐, b‐, and c‐axis of the orthorhombic crystal structure and a‐axis of the hexagonal phase were then calculated. The crystalline orientation behavior of the lower octene copolymers (S‐1, S‐2, and S‐3) are similar and can be represented as a “row‐nucleated“ structure. However, the orientation behavior of S‐4 was different. The uniaxial mechanical properties were also measured. The Young's modulus and tensile strength generally increased with birefringence for all polymers. With increasing content of octene, the Young's modulus showed a decrease from semicrystalline thermoplastic toward an elastomer. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 9–22, 2004     

Numerical simulation of the spin‐draw process of poly(ethylene terephthalate) fibers

Numerical simulation for the calculation of the profile developments of the spin‐draw process in the melt spinning of poly(ethylene terephthalate) was performed. Both spinning and drawing profiles were analyzed and included the structure development of birefringence and crystallinity in the draw line. By applying a simple model describing the continuous drawing process, we made it possible to simulate the spin‐draw process. The strain rate of the spinline had a broad distribution, and that of the draw line had a narrower peak. The calculated birefringence ranged from 0.176 to 0.192 and the crystallinity ranged from 0.37 to 0.44 with draw ratio. The birefringence profile had a similar pattern as the stress profile, and the crystallinity gently increased along the draw line more than the birefringence did. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 2522–2527, 2007