Spinning Techniques

Engr. Shan Imtiaz

Definition

Spinning is the process used to convert the materials into fibers.

Spinning Methods
The method of spinning selected to manufacture certain fibers is dependent primarily on the chemical composition of the fiber. Some fibers can be manufactured by more than one method. The three most commonly used methods for spinning are
1. Melt spinning 2. Dry spinning and 3. Wet spinning

Gel spinning is a comparatively new technology

used more for high performance fibers.

Steps
Three main steps used in spinning techniques 1.Conversion of a polymer into a liquid or spinning solution, also called a dope. 2.Extruding the solution through a spinneret i.e. pumping the dope 3.Solidification of the liquid into filaments (solid)

Spinnerets
To produce the manmade fibres the polymer in solution or molten form is passed through a spinneret (a bathroom shower like screen with very small holes). The spinneret converts the solution in very thin streams which are then solidified to form fibres. The shape and size of the fiber can be easily changed by changing the shape and size of the spinneret. Rate of holes per spinneret may be 100000 numbers per square inch and space of holes in the spinneret could be varied.

Melt Spinning
Melt Spinning is used to manufacture thermoplastic fibers such as nylon and polyester. The melt spinning process is the simplest and least expensive spinning method.

Melt Spinning

Melt Spinning
Polymer is heated and it melts to form a liquid spinning solution. Chips of polymers are fed to a hopper which is heated. There is a grid (sieve) at the base which permits only molten liquid to pass through. Extrusion is done through spinneret vertically. Solidification is done by cooling, for which cool air currents are used.

 For polymers which cannot be converted into molten stage, two options exists Dry Spinning Wet Spinning

Dry Spinning
Dry spinning used to manufacture fibers that can easily be dissolved in a solvent and then recovered without a change in the polymer properties. Acetate, acrylic, modacrylic, and spandex fibers are manufactured using the dry spinning method. In this case, a volatile solvent (acetone) is used to dissolve the polymer and form a solution. Extrusion is also in a vertical position. Solidification by evaporation occurs when filaments come in contact with warm air currents.

Dry Spinning
The following steps are required for using the dry spinning process:
1. Dissolving the fiber-forming substance in a solvent 2. Filtering the fluid 3. Extruding the fluid through the spinneret 4. Solidifying the fiber by evaporating the solvent using warm air (solvent is recovered and reused) 5. Stretching or drawing the partially solidified fiber

Wet Spinning
This is the oldest method of man made yarn manufacturing. Rayon, spandex, and some acrylic fibers are produced using the wet spinning method. A non-volatile solvent is used to convert the raw material (polymer) into a solution. The solution is extruded directly in a horizontal position into the precipitating liquid, this process for making fibers is called wet spinning. The spinneret is submerged in a chemical bath that causes the fibre to precipitate, and then solidify, as it emerges. Solidification occurs through coagulation.

Comparison

MELT Disadvantages Separate drawing step (unless spin draw)

DRY Slow speed (200-400 yds/min) Solvent recovery

WET Slow(70-150 yds/min) Solvent and chemical recovery

Flammable solvent hazards

Advantages High speed (275 to 1500 yds/min) (4000 yds/min spin draw) Yarn does not require purification

Washing to remove impurities

Large tows can be handled

No solvents No purification problems

Gel spinning
It is also known as dry-wet spinning because the filaments first pass through air and then are cooled further in a liquid bath. Gelled resins are spun into fibers. In the gelstate, the fibers are partially bonded together, resulting in increased orientation, and hence higher strength, than that which results from the other spinning processes. Examples are polyethylene and aramid fibers.

Spinning Techniques (Schematic Diagram)

Secondary processes
After spinning, the fibers may be further treated to improve properties, especially stiffness and strength. Secondary processes include cooling, annealing, drying, and, most important, drawing.

Drawing
Drawing is stretching the solid fiber. This increases orientation and further induces crystallization or reforming of crystals in the oriented state.