Melt spinning process description

Vapor grown carbon fiber (VGCF) is the descriptive name of a class of carbon fiber which is distinctively different from other types of carbon fiber in its method of production, its unique physical characteristics, and the prospect of low cost fabrication. Simply stated, this type of carbon fiber is synthesized from the pyrolysis of hydrocarbons or carbon monoxide in the gaseous state, in the presence of a catalyst in contrast to a melt-spinning process common to other types of carbon fiber. 

Because of its extremely low solubility in low-boiling and inexpensive organic solvents, nylon 66 required a new technique for converting the solid polymer into fibers hence the development of melt spinning, the third basic method for producing manufactured fibers. The following description refers essentially to nylon 66 because it was the first to use the method, but the process applies, in general, to all melt-spun manufactured fibers. 

Polymers owe much of their attractiveness to their ease of processing. In many important teclmiques, such as injection moulding, fibre spinning and film fonnation, polymers are processed in the melt, so that their flow behaviour is of paramount importance. Because of the viscoelastic properties of polymers, their flow behaviour is much more complex than that of Newtonian liquids for which the viscosity is the only essential parameter. In polymer melts, the recoverable shear compliance, which relates to the elastic forces, is used in addition to the viscosity in the description of flow [48]. 

Several methods for both melt and gel spinning have been developed, differing in certain details of the process. A schematic description of the basic steps of these various procedures is given in Table 22.11. 

In the modelling of industrial processing of flexible chain polymer melts we often need physically sensible description of the crystallization kinetics. Usually, the melt is subjected to time-dependent deformation rates (fibre spinning,... 

Our analysis of fiber spinning in this chapter will be based on an inelastic rheological model of the stresses. This rheological description appears to be adequate for polyesters and nylons, which comprise the bulk of commercial spinning applications, and our spinning model is essentially the one used in industrial computer codes. This is a process in which melt viscoelasticity can sometimes play an important role, however, and we will revisit the process in Chapter 10. 

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