Melt spinning.

Melt spinning typically is used to make fibers from polyolefins, nylons, and polyesters. One major advantage of melt spinning is that it does not require a purification step since no solvent is used. Another advantage is that melt spinning has very high production speed, which ranges from several hundred meters per minute to several thousand meters per minute. 

Phase Morphology Variations in Processing Operations 1.3.3.1 Melt Spinning 

Mini-fibers have also been observed by Liang et al. [159] on melt spinning polypropylene/polyamide blends. The diameters of the dispersed polyamide 6 phase mini-fibers are tens of microns and more. This is clearly due to the large interfadal tension in this system (polypropylene/polyamide 6) as compared to polyethylene/ polystyrene blends of Min et al. (Table 1.1). 

---

Cakmak M, Teitge A, Zachman FI G and White J L 1993 On-line small-angle and wide-angle x-ray scattering studies on melt-spinning poly(vinylidene fluoride) tape using synchrotron radiation J. Polym. Sc/. 31 371- 81... 

In melt spinning the polymer is heated above its melting point and the molten polymer is forced through a spinneret. Spinnerets are dies with many... 

The equipment for the slit-film fiber process is shown in Figure 15 (29). An olefin film is cast, and as in melt spinning, the morphology and composition of the film determine the processing characteristics. Fibers may be produced by cutting or slitting the film, or by chemomechanical fibrillation. 

In the spunbond process, the fiber is spun similarly to conventional melt spinning, but the fibers are attenuated by air drag appHed at a distance from the spinneret. This allows a reasonably high level of filament orientation to be developed. The fibers are directly deposited onto a moving conveyor belt as a web of continuous randomly oriented filaments. As with meltblown webs, the fibers are usually thermal bonded or needled (53). 

Mechanical Properties. Polyester fibers are formed by melt spinning generally followed by hot drawing and heat setting to the final fiber form. The molecular orientation and crystalline fine stmcture developed depend on key process parameters in all fiber formation steps and are critical to the end use appHcation of the fibers. 

Synthetic Fiber and Plastics Industries. In the synthetic fibers and plastics industries, the substrate itself serves as the solvent, and the whitener is not appHed from solutions as in textiles. Table 6 Hsts the types of FWAs used in the synthetic fibers and plastic industries. In the case of synthetic fibers, such as polyamide and polyester produced by the melt-spinning process, FWAs can be added at the start or during the course of polymerization or polycondensation. However, FWAs can also be powdered onto the polymer chips prior to spinning. The above types of appHcation place severe thermal and chemical demands on FWAs. They must not interfere with the polymerization reaction and must remain stable under spinning conditions. 

HoUow-fiber fabrication methods can be divided into two classes (61). The most common is solution spinning, in which a 20—30% polymer solution is extmded and precipitated into a bath of a nonsolvent, generally water. Solution spinning allows fibers with the asymmetric Loeb-Soufirajan stmcture to be made. An alternative technique is melt spinning, in which a hot polymer melt is extmded from an appropriate die and is then cooled and sohdified in air or a quench tank. Melt-spun fibers are usually relatively dense and have lower fluxes than solution-spun fibers, but because the fiber can be stretched after it leaves the die, very fine fibers can be made. Melt spinning can also be used with polymers such as poly(trimethylpentene), which are not soluble in convenient solvents and are difficult to form by wet spinning. 

Extmsion technology is used to produce spunbond, meltblown, and porous-film nonwovens. Fabrics produced by these systems are referred to individually as spunbonded, meltblown, and textured- or apertured-film nonwovens, or genericaHy as polymer-laid nonwovens. These fabrics are produced with machinery associated with such polymer extmsion methods as melt-spinning, film casting, and extmsion coating. In polymer-laid systems, fiber stmctures are simultaneously formed and manipulated. 

Tensile Properties. Tensile properties of nylon-6 and nylon-6,6 yams shown in Table 1 are a function of polymer molecular weight, fiber spinning speed, quenching rate, and draw ratio. The degree of crystallinity and crystal and amorphous orientation obtained by modifying elements of the melt-spinning process have been related to the tenacity of nylon fiber (23,27). 

Optical properties also provide useful stmcture information about the fiber. The orientation of the molecular chains of a fiber can be estimated from differences in the refractive indexes measured with the optical microscope, using light polarized in the parallel and perpendicular directions relative to the fiber axis (46,47). The difference of the principal refractive indexes is called the birefringence, which is illustrated with typical fiber examples as foUows. Birefringence is used to monitor the orientation of nylon filament in melt spinning (48). 

AH commercial linear polyamides that melt at or below 280°C are melt- rather than solution-spun into fiber because melt spinning is more economical. 

Both fiber producers and fabric mills have realized that many of the performance variants that are difficult to iacorporate iato fiber melt spinning can be accompHshed by post-treating yams or fabrics. Mills ia the 1990s can apply flame retardants, softeners, dye-fade inhibitors, and stain- and soil-resisting agents as part of the finishing of a fabric. 

---