Deformation of dispersed polystyrene droplets in immiscible polypropylene/polystyrene blend fibers under uniaxial elongational flow

The deformation of dispersed polystyrene (PS) droplets in immiscible polypropylene (PP) matrices during melt spinning of blend fibers were simulated by adopting the droplet deformation criteria. The ratios of number-average length to diameter were measured through morphology analysis, and compared with the simulated values. It was found that the adopted deformation models described the deformation behavior of the dispersed droplets during melt spinning very well. Dispersed droplets in the center of the fiber tend to be stretched longer than those of near to the surface, due to the radial temperature gradient during fiber formation. Moreover, combining with the rheological studies of raw materials, a theoretical relation between temperature and deformation was established and used to determine the radial temperature differences along the spinning line. It was found that the radial temperature gradients vary from 0.22 to 0.35 °C/μm at 40 cm beneath to the spinneret at the discussed take-up velocities.     

Studies on melt spinning of sea-island fibers. I. morphology evolution of polypropylene/polystyrene blend fibers

Isotactic polypropylene/atactic polystyrene (iPP/aPS) immiscible polymer blends are prepared and are melt-spun to prepare blend fibers with matrix-fibril morphologies. The running fibers are captured at different positions of the spinning line, and the morphologies including dispersions of aPS droplets in iPP matrix fibers, droplets diameter and their distributions, as well as the radial gradients on counts and diameter of droplets are analyzed. The effect of take-up velocity on the morphology of take-up fibers is discussed by comparing with that of extrudate fibers. At low take-up velocities, the enhanced radial gradients are attributed to shrinking of matrix fibers on the elongation of spinning stress. While the effects of non-uniform deformation, coalescence and migration of droplets play a role to resist the effects of shrinking of matrix fibers at high take-up velocities. Based on morphology analysis, the mechanisms of compression from the shrinking of matrix fibers, non-uniform deformation, coalescence and migration of droplets are presented to explain why and how the radial gradients form.     

Comparison of the structure-property relationships for PTT and PET fibers spun at various take-up speeds

A comparison of poly(trimethylene terephthalate)(PTT) and poly(ethlene terephthalate)(PET) fibers spun at various take-up speeds was presented. Fiber characterization included tensile and thermal properties, optical birefringence, density, sonic modulus, boil-off shrinkage, and wide-angle X-ray diffraction. The phenomenon of stress-induced crystallization was inferred from the X-ray diffraction diagrams for fibers spun with take-up speeds over 4000 m/min. The tenacity and elongation of PTT and PET fiber showed typical results, but the initial modulus of PTT fiber was nearly unchanged over the entire take-up speed range (2000–7000 m/min), whereas that of PET, as expected, increased monotonically with increasing take-up speed. This divergent behavior could be explained by the different molecular deformations in the c-axis as determined from X-ray diffraction patterns. The fiber crystallinity, density, and heat of fusion of both polymers increased with take-up speed. The boil-off shrinkage decreased with increasing take-up speed. The optical birefringence of the two fiber types showed a maximum level at a take-up speed of ca. 5000 m/min. The melting temperature behavior of PTT fiber was different from that of PET fibers. It was found that PTT is less sensitive to stress induced changes at high spinning speeds than is PET.     

Structure and properties of syndiotactic polystyrene fibers prepared in high-speed melt spinning process

High-speed melt spinning of syndiotactic polystyrene was carried out using high and low molecular weight polymers, HMs-PS and LMs-PS, at the throughput rates of 3 and 6 g/min. The effect of take-up velocity on the structure and properties of as-spun fibers was investigated. Wide angle X-ray diffraction (WAXD) patterns of the as-spun fibers revealed that the orientation-induced crystallization started to occur at the take-up velocities of 2–3 km/min. The crystal modification wasα-form. Birefringence of as-spun fibers showed negative value, and the absolute value of birefringence increased with an increase in the take-up velocity. The cold crystallization temperature analyzed through the differential scanning calorimetry (DSC) decreased with an increase in the take-up velocity in the low speed region, whereas as the melting temperature increased after the on-set of orientation-induced crystallization. It was found that the fiber structure development proceeded from lower take-up velocities when the spinning conditions of higher molecular weight and lower throughput rate were adopted. The highest tensile modulus of 6.5 GPa was obtained for the fibers prepared at the spinning conditions of LMs-PS, 6 g/min and 5 km/min, whereas the highest tensile strength of 160 MPa was obtained for the HMs-PS fibers at the take-up velocity of 2 km/min. Elongation at break of as-spun fibers showed an abrupt increase, which was regarded as the brittle-ductile transition, in the low speed region, and subsequently decreased with an increase in the take-up velocity. There was a universal relation between the thermal and mechanical properties of as-spun fibers and the birefringence of as-spun fibers when the fibers were still amorphous. The orientation-induced crystallization was found to start when the birefringence reached — 0.02. After the starting of the orientation-induced crystallization, thermal and mechanical properties of as-spun fibers with similar level of birefringence varied significantly depending on the processing conditions.     

The non-uniform phase structure in blend fiber. I. Non-uniform deformation of the dispersed phase in melt spinning

By melt spinning of incompatible polymer blends, the deformation of the dispersed phase was investigated in the fiber spinning process, for polypropylene/polystyrene (PP/PS) blend fiber and low density polyethylene/polyamide 6 (LDPE/PA6) blend fiber, respectively. Two kinds of the take-up fiber all exhibit the matrix fibrillar morphology, but with the opposite morphology. For PP/PS take-up fiber, the dispersed PS fibrils were finer in the core than near the surface. On the contrary, the dispersed PA6 fibrils were finer near the surface than in the core for LDPE/PA6 take-up fiber. However, for the special fiber in which the extensional flow was absent, there was the uniform morphology in either PP/PS or LDPE/PA6. Thus, fibrils’ non-uniform deformation, occurred in the drawing process, was considered to be due to the radial non-uniform processing conditions across the spin-line cross-section. The distribution of fibrils’ diameter was also investigated on the whole cross section. Rheological properties of each component were measured by the capillary rheometer. The non-uniform phase structure in blend fiber is a new phenomenon in the extensional flow.     

Air-gap spinning of cellulose/ionic liquid solution and its characterization

In order to study the effects of the spinning conditions on the structure and the properties of the regenerated fiber, cellulose was dissolved in ionic liquid and then spun into fiber using an air-gap spinning process. The solution concentration, the take-up speed and the fixation of the fiber ends during coagulation improved the crystallinity and the tensile strength at the same time. The fiber surface became smooth by addition of DMF (dimethylformamide). However, it decreased the crystallinity and the tensile strength of the fibers. We revealed that the developed structure during coagulation determined the morphology and the properties of the fibers. The co-solvent resulted in smooth surface of the fiber and also changed the mechanical properties.     

Experimental study and prediction of the diameter of melt-electrospinning polypropylene fiber

Firstly, the effects of the spinning temperature, spinning voltage, tip-to-collector distance and ambient temperature on the diameter of melt-electrospinning polypropylene (PP) fibers were studied. The results showed that with the increase of the spinning temperature, spinning voltage and tip-to-collector distance, the fiber diameters first decreased and then increased. However, when the ambient temperature increased, the fiber diameters increased gradually. Secondly, based on the previous results, the response surface methodology (RSM) was used to investigate the combined effects of processing parameters on fiber diameters and establish a second-order polynomial equation to predict the fiber diameter. The results showed that the effect order of four factors on fiber diameter was as follows: spinning temperature > tip-to-collector distance > ambient temperature > spinning voltage. Moreover, the fiber diameter predicted by response surface analysis fitted well with the experimental result. Finally, three layer melt-electrospinning PP webs with different fiber diameters were online compounded with conventional non     

Spinnability in pre-gelled gel spinning of polyacrylonitrile precursor fibers

The spinnability in pre-gelled gel spinning of polyacrylonitrile (PAN) precursor fibers was investigated. The spinning solutions were aged at 25 °C for different times prior to fiber spinning. The pre-gelled spinning solution aged for 2.5 h was much more strain hardening than the ungelled one, which can increase the spinnability of the solution. The maximum take-up velocity of the first winding roller V _1m, which reflects the spinnability of the spinning solutions, was found to be largest when the aging time was 1.5 h. The spinnability increased with the increase of the air gap length and the lengthdiameter ratio L/D of the spinnerette. Once the L/D increased beyond 15, the spinnability hardly changed. The fibers spun from the spinning solution aged for 1.5 h had the best mechanical properties and favorable structure, showing that good spinnability favors the performance increase of resultant PAN precursor fibers.     

Mechanical properties of wool fiber in the stretch breaking process

Short wool fibers obtained by the stretch breaking process can be blended with cotton fibers and processed in a cotton spinning system, which has a high production rate. For the structural property of the wool fiber after stretch breaking, the diameter and length of the wool fiber were measured as a function of time. The diameter of the broken fibers was finer than the diameter of untreated fibers. The fiber diameter at the break point was the finest and was more irregular than the original fiber. The broken fiber showed mechanical properties of increased modulus, decreased breaking strain, and increased breaking strength.     

Optimization of melt-spinning parameters of poly(ethylene terephthalate) partially oriented multi-filament yarn in an industrial scale: Central composite design approach

In this study, central composite design (CCD) based on response surface methodology (RSM) was employed to optimize parameters of melt-spinning process of poly(ethylene terephthalate) partially oriented multifilament yarn (POMFY). On the basis of a four-variable CCD, RSM was used to determine the effects of spinning temperature, spinning pressure, take-up velocity and quenching air velocity on the levels of the elongation of POMFY as the response. The POMFY samples were also characterized by scanning electron microscopy (SEM) and energy dispersive X-ray (EDX) analysis. By applying a quadratic regression analysis, an equation indicating the effect of each variables on the response was developed. The predicted values of the parameters showed excellent agreement with the experimental values (R ²=0.9565, Adjusted-R ²=0.916). Moreover, the results confirmed that the CCD mathematical model was a suitable method to optimize the melt-spinning parameters of POMFY in an industrial scale.     

The non-uniform phase structure in blend fiber. II. The migration phenomenon in melt spinning

The migration phenomenon was investigated in polypropylene/polystyrene (PP/PS) blend fiber and low density polyethylene/polyamide 6 (LDPE/PA6) blend fiber. The migration of fibrils in melt spinning was evaluated by the variation of fibrils’ area ratio over the cross section of blend fiber. In PP/PS blend fiber, the dispersed PS deformed into many highly oriented fibrils in the PP matrix, and PS fibrils migrated towards the surface of the take-up fiber in the fiber spinning process. On the contrary, PA6 fibrils migrated into the core of the take-up fiber, while the dispersed PA6 deformed into many highly oriented fibrils in the LDPE matrix for LDPE/PA6 blend fiber. Otherwise, no migration phenomenon was observed in the special fiber that was prepared without any drawing, neither in PP/PS nor in LDPE/PA6. Therefore, in the fiber spinning process, the migration phenomenon actually occurred mainly in the drawing process, which is the non-isothermal uniaxial extensional flow. Comparing with migration mechanisms in the shear flow, the migration phenomenon in melt spinning was probably due to the radial non-uniform extensional stress, the extensional viscosity.     

An improved Lagrangian approach for simulating fiber whipping in slot-die melt blowing

Melt blowing is a one-step approach for manufacturing microfibrous nonwovens. In slot-die melt blowing, a pair of air jets with high velocity and temperature is applied on the polymer and attenuates the polymer in to fibers. The fiber motion which was called vibration or whipping plays a crucial role in expressing the drag mechanism. In this study, an improved Lagrangian numerical approach was utilized to simulate the fiber whipping in melt blowing. The fiber whipping simulated in this study was significantly improved compared to other previous works. Meanwhile, the fiber diameter, fiber velocity and fiber temperature below the spinneret were simulated. The numerical simulation indicated that the most attenuation of fiber diameter occurred within 0.07 m below the spinneret; the fiber velocity increased gradually while the air velocity decreased rapidly along the spinning line, and the fiber velocity exceeded the air velocity where below a critical z-position; In addition, the fiber temperature decreased tardier than the decreasing of air temperature. This study illustrated that it was important to optimal design the air flow field which was supposed to fully utilize the air velocity and temperature together. In addition, the energy saving of melt blowing deserved to be taken into consideration.     

Matrix-fibril morphology development of polypropylene/poly(butylenes terephthalate) blend fibers at different zones of melt spinning process and its relation to mechanical properties

Different shapes of dispersed phase such as sphere, laminar and fibrillar can form in the matrix phase of polymer blends. Production of blend fibers in melt spinning process can result more effective in fibrillar phase morphology formation than in other processes. In this research, the matrix-fibril morphology development during the melt spinning of polypropylene/poly(butylenes terephthalate) was studied. The shapes of blend dispersed phase collected from different zones of the melt spinning line were evaluated by scanning electron micrographs (SEM) and rheological mechanical spectra (RMS). The results showed that fibrillar shape could not be created in the PP/PBT blend fiber samples exited from the spinneret orifice (gravity spun fibers) at low contents (5 percent) of the PBT dispersed phase. However, a complete fibrillar structure was formed in all the as-spun PP/PBT blend fiber samples (melt drawn). The rheological evaluations confirmed a network structure resulting from fibril formation for the samples with high contents (20–40 %) of the PBT dispersed phase and the formation of spherical shape with low contents (5–10 %) of the PBT dispersed phase in matrix of the blend fibers. It was observed that the flow fields of processing zones and blend ratio, in producing the blend fibers, have intensive effects on morphological variations; besides there was a strong relation between the mechanical and morphological properties.     

Fabrication and Characterization of Poly(L-lactic Acid) Fiber Mats Using Centrifugal Spinning

Polylactic acid (PLA) fine fibers and multi walled carbon nanotube (MWCNT) reinforced PLA fine fiber composites were developed utilizing a centrifugal spinning process. Chloroform and chloroform combined with dimethylformamide (DMF) were used to prepare solutions with varying concentrations of PLA and MWCNTs. The optimum spinning conditions to produce PLA fibers and its composites were determined. The morphology of the fibers was analyzed using scanning electron microscopy. In addition, X-ray diffraction analysis and thermo-physical characterization was conducted using thermogravimetric analysis and differential scanning calorimetry. PLA fibers with an average diameter of 481 nanometers and PLA/MWCNT fibers with an average diameter of 358 nanometers were obtained. A decrease in the crystallinity of the fibers was observed when compared to bulk PLA values.     

Structural analysis of finer cotton yarns produced by conventional and modified ring spinning system

Yarn structure plays an important role in determining the properties of spun yarns. Recently, a modified spinning technique has been developed for producing a low torque and soft handle singles yarn by modifying the fiber arrangement in a yarn. Comparative studies revealed that the finer modified yarns possess significantly higher strength and lower hairiness over the conventional yarns of the same twist level, implying a different structure of finer modified yarn. Thus this paper aims to quantitatively study the structures of the finer conventional and modified cotton yarn (80 Ne) produced at the same twist level. Various measuring techniques, namely the Scanning Electron Microscope (SEM), cross section technique and tracer fiber technique, are adopted to analyze their structural characteristics, including fiber configuration, fiber spatial orientation angle, fiber packing density, yarn surface appearance, and fiber migration behavior. Results showed that finer modified yarns exhibit a smoother surface and much more compact structure with less hairiness. The fibers in the finer modified yarn have a complicated fiber path with relatively lower fiber radial position, larger migration frequency and magnitudes. In addition, it was noted that 73% of fibers in the finer conventional yarn follow concentric conical helix, which is contrary to those in the coarser conventional yarn. The analyses conducted in this paper provide deep insights into the mechanism of modified spinning technique and evidential explanations on the difference of properties between the finer conventional and modified yarns.     

Preparation of regenerated cellulose fiber via carbonation (II)

Sodium cellulose carbonate (CC-Na) dissolved in 8.5 wt% NaOH/ZnO (100/2–3, w/w) aqueous solution was spun into some acidic coagulant systems. Diameter of regenerated cellulose fibers obtained was in the range of 15–50μm. Serrated or circular cross sectional views were obtained by controlling salt concentration or acidity in the acid/salt/water coagulant systems. Velocity ratio of take-up to spinning was controlled up to 4/1 with increasing spinning velocity from 5 to 40 m/min. Skin structure of was developed at lower acidity or higher concentration of coagulants. Fineness, tenacity and elongation of the regenerated cellulose fibers were in the range of 1.5–27 denier, 1.2–2.2 g/d, and 8–11.3%, respectively. All of CC-Na and cellulose fibers spun from CC-Na exhibited cellulose II crystalline structure. Crystallinity index was increased with increasing take-up speed.     

Effect of Basalt Fiber on the Strength Properties of Polymer Reinforced Sand

This paper displays an experimental study of the effect of basalt fiber on the strength properties of polymer reinforced sand. Laboratory trials of unconfined compression test (UCS), direct shear test, and tensile test were conducted on the specimens treated with polymer and basalt fiber, and several factors including polymer content, fiber content and dry density of sand that will influence the strength behaviors are investigated in detail. Based on test results and scanning electron microscope (SEM) images, the reinforcement mechanism was analyzed. The results showed that the polymer content, basalt fiber content and dry density of sand had greatly improved the strength behaviors of reinforced specimens. The increase in polymer and fiber content had an active effect on strength characteristics, while the angle of internal decreased slightly. The strength properties were enhanced with the increase in dry density, and the effect of dry density on tensile strength is affected by fiber content. The presence of randomly distributed fibers has formed a spatial fiber-sand net in sand, and the additive of polymer solution formed membrane to enwrap sand particles and connect sand and fibers, thereby formed a stable structure in sand. These structures have increased the bonding and interlocking forces between sand and fibers, and decreased the void ratio of reinforced specimens.     

A new approach of prediction of yarn diameter

In the present study, an attempt has been made to obtain the relationships for prediction of yarn diameter from different fibers and spinning technologies. The Peirce formula is found to give high deviation from the observed values of yarn diameter because it does not take the effect of twist, type of fibre and spinning technology into consideration. A new empirical model has been proposed that takes into account the parameters affecting the yarn diameter to a great extent, namely yarn twist, spinning technology and type of fibre in calculating the yarn diameter. The spinning technology, type of fibre and the proportion of fibre in the yarn have significant effect on yarn diameter. The proposed model is able to predict the yarn diameter more accurately.     

Diameter variations of irregular fibers under different tensions

The cross-section area of animal fibers varies along the fiber length, and this geometrical irregularity has a major impact on the mechanical properties of those fibers. In practice fibers are often subjected to tensile stresses during processing and application, which may change fiber cross-section area. It is thus necessary to examine geometrical irregularity of fibers under tension. In this study, scoured animal fibers were subjected to different tensile loading using a Single Fiber Analyzer (SIFAN) instrument. The 3D images of the fiber specimens were first constructed, and then along-fiber diameter irregularities of the specimens were analyzed for different levels of tensile loading. The changes in effective fineness of the fiber specimens were also discussed. The results indicate that for the wool fibers examined, there is considerable discrepancy in the fiber diameter results obtained from the commonly used single scan along fiber length and that from multiple scans at different rotational angles, and that the diameter variation along fiber length increases as fiber tension increases. The results also show that when diameter reduction treatments are applied to wool by stretching, the reduced average fiber diameter is associated with an increase in both within-fiber and between-fiber diameter variations. So in terms of effective fineness, the change is much smaller than the difference between the average diameters of the parent and treated wool. These results have significant implications for improving the accuracy of fiber diameter measurement and evaluation.     

Poly(trimethylene terephthalate) fiber melt-spinning: Material parameters and computer simulation

In this work, the method, in principle of the box complex algorithm was adopted to obtain stress-induced crystallization coefficient C and the strain-optical coefficientA _op with the value of 295 and 1.5×10⁻⁹, respectively, and some parametersA ₁=0.27,A ₂=5.06,a=3.5,b=1.8 relative to the elongational viscosity of poly(trimethylene terephthalate)(PTT) fiber. The vitrification distance as a function of the take-up velocity and mass throughput was also gotten. The effects of spinning conditions on filament temperature, velocity gradient, spinning tension, birefringence and crystallinity, and effect of viscoelasticity on take-up velocity had been discussed.