Spinning process

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Dry Spinning. On a worldwide basis, about 90% of all spandex fibers are produced by various adaptations of dry spinning (15,16). The solution dry spinning process is illustrated in Figure 5. The polymer spinning solution is metered at a constant temperature by a precision gear pump... 

The People s RepubHc of China introduced Kuraray technology and started production of PVA fiber by a wet spinning process in 1965. Its annual capacity reached 165,000 tons in 1986 (9). The Democratic People s RepubHc of Korea produce PVA and reportedly have an annual production capacity of 50,000 tons (9). 

Other Spinning Processes. The following examples are of scientific interest but have not been employed on an industrial scale. 

In another laboratory at Kew, C. H. Steam and C. E. Topham, who had worked for Sir Joseph Swan on lamp filaments, developed the continuous filament spinning process (8) and the machinery needed to wash and coUect (9,10) the yams. A fibermaking method was outlined in 1898, and the Viscose Spinning Syndicate was formed to develop the concept into a commercial proposition. 

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. 

In a typical commercial dry jet-wet spinning process, PPT polymer of inherent viscosity 6.0 dL/g is added to 99.7% sulfuric acid in a water-jacketed commercial mixer in a ratio of 46 g of polymer to 100 mL of acid. The mixture is sealed in a vacuum of 68.5—76 mL of mercury. Mixing takes place for 2 h... 

In most spinning processes, the fiber emerging from the spinneret is drawn down to a desired dimension before complete solidification. In some production lines, a laser beam is uti1i2ed to monitor the dimensions of emerging thread any alteration is recorded and if required, the dope deHvery rate, take-up rate, and internal-injection medium deHvery rate are adjusted automaticaUy. 

One report (13) describes the procedure for spinning dry asymmetric ceUulose acetate fiber with a bore skin. Such fibers are spun in a modified dry-spinning process in which a volatile Uquid (methyl formate) is used as the ceUulose acetate solvent. The bore coagulating Uquid is isopropyl alcohol, which is subsequentiy removed. The advantages of these dry fibers over most ceUulose acetate membranes are that they can be stored dry, they are wet-dry reversible, they can be sterilized and packed dry, and they are ready for use without removal of preservatives. 

Because of the rotation of the N—N bond, X-500 is considerably more flexible than the polyamides discussed above. A higher polymer volume fraction is required for an anisotropic phase to appear. In solution, the X-500 polymer is not anisotropic at rest but becomes so when sheared. The characteristic viscosity anomaly which occurs at the onset of Hquid crystal formation appears only at higher shear rates for X-500. The critical volume fraction ( ) shifts to lower polymer concentrations under conditions of greater shear (32). The mechanical orientation that is necessary for Hquid crystal formation must occur during the spinning process which enhances the alignment of the macromolecules. 

Spinnerette Process. The basic spinning process is similar to the production of continuous filament yams and utilizes similar extmder conditions for a given polymer (17). Fibers are formed as the molten polymer exits the >100 tiny holes (ca 0.2 mm) of each spinnerette where it is quenched by chilled air. Because a key objective of the process is to produce a relatively wide (eg, 3 m) web, individual spinnerettes are placed side by side in order that sufficient fibers be generated across the width. This entire grouping of spinnerettes is often called a block or bank, and in commercial production it is common for two or more blocks to be used in tandem in order to increase the coverage and uniformity of laydown of the fibers in the web. 

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). 

Fig. 7. Spin-drawing processes for nylon yam (a) draw-twisting process, (b) conventional spinning process, and (c) coupled process.

Fig. 12. Spinning process for partially oriented nylon yam (97). Winder speed is between 4500 and 6500 mpm.

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