the production of manufactured fibers. why use manufactured fibers? easy to control quantity can...
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The Production of Manufactured Fibers
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Why use manufactured fibers? Easy to control quantity Can tailor properties to meet end-
use needs Blending Not evil
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Categories
Inorganic fibers Glass, metal, ceramic
1st generation manufactured fibers Regenerated from natural materials
(cellulose) 2nd generation manufactured fibers
Synthetics – from petroleum products 3rd generation manufactured fibers
High-performance/high-tech fibers (last 20 years)
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The Fiber-Manufacturing Process Fiber spinning:
Prepare viscous dope or melt;
Extrude dope or melt through spinneret to form fiber;
Solidify fiber by coagulation, evaporation, or cooling.
Raw material: Substance to form solution.
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Manufacturing Fibers
Spinning solution (dope, melt): Material from which fiber is formed.
Extrusion: Forcing dope or melt through tiny holes in the spinneret.
Spinneret: Small nozzle through which dope/melt is forced.
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Methods of Manufacturing Fibers
• Melt spinning: Resin solids melted, fiber spun into air, cooled
• Wet spinning: Raw material dissolved by chemicals, fiber spun into chemical bath and coagulated.
• Dry spinning: Resin solids dissolved by solvent, fiber spun into warm air, solvent evaporates.
• Solvent spinning: polymer is dissolved and extruded into solvent, which can be recycled.
• Others: Gel spinning; Emulsion spinning
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Melt spinning
Dry spinning
Wet Spinning
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Fiber Modifications
Parent fiber: Fiber in its simplest form.
Modifications: Changes of parent fiber relative to properties or chemical composition; engineered for end use.
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Spinneret Modifications
Fiber size: Control size of spinneret opening, amount of drawing, or extrusion rate; size based on end use. Apparel: less than 7 denier Furnishings: 5-25 denier Industrial: any size Microdenier: less than 1.0 denier per filament
(dpf) Ultrafine fibers: Smaller than microdenier fibers Mixed denier fiber bundling: Combines regular
size fiber with microfibers in a yarn.
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Spinneret Modifications (cont.)
Fiber shape: Alter properties. Solid fibers: Even diameter. Thick-thin fibers: Uneven
diameter. Hollow/multicellular fibers:
Use gas-forming compounds, inject air, or modify spinneret hole.
Trilobal shape: Three-sided fiber cross sectional shape designed to imitate silk.
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Spinneret Modifications (cont.)
Molecular structure & crystallinity modifications High tenacity fiber types:
Draw or stretch to increase orientation. Chemical modifications increase DoP.
Low-pilling: Decrease molecular weight slightly to reduce flex life and decrease pilling.
Binder staple: Polyester with very low melting point.
Low-elongation modifications: Reinforcing fibers to blend with cellulosic fibers.
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Drawing
Stretching fiber Improves tenacity
(strength) Aligns molecules –
orientation Thinner
Partially oriented yarns
Fully oriented yarns
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Texturing
Bulkier yarns Opaque yarns Elastomeric yarns
Can be cut for Tow
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Additives to Polymer or Spinning Solution
Delustering: Titanium dioxide reduces luster; produces dull, not bright fibers.
Solution dyeing or mass pigmentation: Colored pigments/dye to spinning solution; gel dyeing; Color added after spinning but before fiber hardens.
Whiteners or brighteners: Resist yellowing.
Cross dyeable or dye affinity: Dye-accepting chemicals incorporated into molecular structure as a direct part of polymer; not colored when extruded.
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Additives to Polymer or Spinning Solution (cont.)
Antistatic: Incorporate conductor of electrons.
Sunlight Resistance: Incorporate sunlight stabilizers.
Flame Resistant: Incorporate flame retardant compound.
Antibacterial: Incorporate a compound that protects from bacterial growth.
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Modifications in Fiber Spinning Self-crimping fibers Fiberfill
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Complex Modifications
Bicomponent fibers: One fiber incorporates two polymers which are chemically different, physically different, or both. If components represent two different generic classes, they are bicomponent bigeneric.
Types: Side-by-side or bilateral Core-sheath or sheath-core Matrix-fibril
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Bicomponent Fiber Structure
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Specialty fiber construction Hollow fibers – insulation
Injected air or gas reaction Microfibers – very fine
Splitting method Sea island method
Fibrillated fibers – coarse fibers fibrillation
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Performance Fibers Used to enhance human
performance. Three layers:
Moisture management layer Warmth or insulation layer Protection layer
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Environmental Impact Perception of
manufactured fibers Amount of
petrochemicals used for fiber production
Effect of fiber production on environment
Concerns Chemical spills Recycling Health and safety
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Environmental Impact (cont.) Regulations, safety concerns, costs,
& image Changes
Use less hazardous chemicals Recycle & manage waste
Dispose of consumer wastes