Staple fiber spinning

Polyester (or other fibers such as nylon or polypropylene) staple fibers can be produced by either a one-step process or a two-step process. The process steps are the same in both cases however, the fiber spinning speed is lower in a one-step process and the fiber is drawn, crimped and heat-set in one continuous machine. These one-step lines generally have smaller capacities and are often fed by extruders. They are mostly used for specialty fibers, such as bicomponents and non-apparel end uses and nonwovens. 

3 Drawing of a Hills bicomponent staple spinning line. 

E Corporation, 2011). Typical fiber cut lengths range from 3 to 6 cm. This length is easily adjusted by changing out the cutter head. The final bales are transferred by tow trucks or automatic handling devices to a warehouse to await shipment (Anon., 2011). 

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B. Baker, Staple Fiber Spinning with Reclaimed Polymers, IF J (June 1995), pp. 34-50. 

The spun yarns used in textile fields are prepared mainly by the cotton or rayon staple fiber-spinning systems. The spun yarns used in the industrial field are produced mainly by the... 

Keywords bulk continuous fibers (BCF), crystallinity, drawing, elasticity, elongation, fiber-forming polymer, fiber monofilament, low oriented yam (LOY), melt blown process, melting, monofilament, multifilament silk, orientation, partially oriented yam (POY), staple fibers, spinning, spunbonded fibers, stmcture, technical fiber, tenacity, textile fiber, texturing. 

Applications of viscose rayon The main application of rayon is as staple fiber. Spinning is carried out from clusters of spinnerets and bundles are processed collectively as a tow. Rayon staple fiber is applied unblended, but is also used in blends with cotton and/or polyester, in outerwear. Filament yarns have become a... 

PTT polymer pellets must be dried to a moisture level of <30 ppm, preferably in a close-loop hot air dryer, to avoid hydrolytic degradation during melt processing. Drying is carried out with 130 °C hot air with a dew point of < -40 °C for at least 4 h. Because of the faster crystallization rate, PTT pellets are already semicrystalline after pelletizing, and do not require pre-crystallization prior to drying as with PET. The dried polymer is extruded at 250-270 °C into bulk continuous filaments (BCFs), partially oriented yam (POY), spin-draw yam (SDY) and staple fiber. 

The spinnability and spinning properties of a polymer are of the highest importance in the manufacturing of staple fibers and filaments. There are many analogies to the production of films, where breaks or splits are concerned. The frequency of yarn breaks determines the economic viability of the production process, as well as the competitiveness and the reputation of the manufacturer. Today, in the age of automation, it would be theoretically possible to manage the processing of the polymer with a minimum of staff if no yam breaks disturbed the processing. 

Finally, the fibers are textured for specific applications. They can be twisted, coiled, or even randomly kinked if they are to be used for carpet piling. More than half of the total carpet-fiber market is based on nylon staple and filaments. When nylon is to be blended with other fibers, the filament is cut into staple fiber—short pieces 3—15 centimeters in length— for subsequent spinning. 

Unlike nylon, which is highly crystalline, PET fibers are amorphous after spinning. They are like the molecules shown at the top of Figure 22-6 in Chapter 22. In order to make a usable textile yarn or staple fiber our of PET, it must be drawn under conditions that result in orientation and crystallinity. This is accomplished by drawing at temperatures of about 175°F with stretch 300-400%. As with nylon, the conditions of draw (especially... 

Melt spinning is not used for polyacrylics because they are sensitive to high temperatures. They actually begin to decompose before they reach melting temperature. Solution spinning is used instead. The dried polymer is dissolved in a polar solvent like acetone or dimethyl formamide (DMF). The spinning mechanics are otherwise the same, except the solvent is recovered as it vaporizes, immediately after the extrusion through the spinneret. Most acrylics are sold and used in the form of staple fiber. 

Fabrics are two-dimensional materials made from fibers. Their primary purpose is to cover things and they are commonly used in clothes, carpets, curtains, and upholstery. The motive for covering may be aesthetic, thermal, or acoustic. Fabrics are made out of or twisted bundles of fibers. The spinning of yams can occur in two ways staple fibers can be twisted into a thread ( spun yam ) or monofilaments can be twisted into a similar usable thread ( filament yam or continuous filament yam ). All these definitions are important in order to understand the conversation of the fiber industry. 

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