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MANUFACTURING METHODS OF MAN-MADE FIBRES AND THEIR COMPARISONS
1. YOGESHWAR SHARMA 17EMBTT105
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A SEMINAR
ON
“ MANUFACTURING METHODS OF MAN-MADE FIBRES AND THEIR
COMPARISONS ”
AT
M.L.V TEXTILE & ENGINEERING COLLEGE
BHILWARA (RAJASTHAN)
"TEXTILE TECHNICAL DEPARTMENT"
Submitted to:
RAJASTHAN TECHNICAL UNIVERSITY, KOTA
SUBMITTED BY: - SUBMITTED TO: -
NAME: - YOGESHWAR SHARMA Mr. PRAKASH KUDE
ROLL NO. 17EMBTT105 (Assistant professor)
M.L.V. TEXTILE & ENGINEERING COLLEGE BHILWARA (RAJASTHAN)
(An Autonomous Engineering college of the Rajasthan Govt.)
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Acknowledgement
It gives me a great sense of pleasure to present the report of B.TECH project undertaken during
B.TECH 4th year. I own special debt of gratitude to Mr. PRAKASH KUDE department of textile
technology, MLVTECH, BHILWARA for this constant support and guidance throughout the
course of my work. His sincerity thoroughness and perseverance have been constant sources of
inspiration for us. It is only his cognizant effort that my endeavors have been light of the day.
I also take the opportunity to acknowledge the contribution of DHIRENDRA SHARMA
(principal sir), MLVTECH, and BHILWARA for his full support and assistance during the
project work.
NAME: - YOGESHWAR
ROLL NO.: -17EMBTT105
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Abstract
The research and development work relating to the science and technology of
man-made fibre s covers a very wide field which includes the manufacture
offibre-torming polymer, conversion of polymer to fibres, manufacture of yarns
and fabrics and their chemical processing The R&D work being done in India in
these different areas is briefly reviewed in this paper with particular reference to
the significant work done during the past ten years or so. Though every attempt
has been made to include the major contributions made by different groups in
the country, the account is by no means comprehensive. Finally, some areas have
been identified, particularly the weak and emerging areas, in which there is a
definite need to strengthen the R&D base.
A fibre is a unit of matter characterized by flexibility, fineness and a high ratio of
length to thickness. Because fibres have a high murface to volume ratio, they can
be extremely strong materials According to their origin, textile fibres may be
classified as natural fibres, when they occur in nature in fibre form, and man
made fibres, when they do not occur in nature in fibre form. This chapter
addresses the relationship between their structure and properties, and their use
in civil engineering applications, such as road construction, bridges, non-structural
gratings and claddings, structural systems for industrial supports, buildings, long-
span roof structures, tanks, thermal insulators,etc.
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TABLE OF CONTENTS
TITLE PAGE NO.
Acknowledgement 2
Abstract 3
MANUFACTURING METHODS OF 5
MAN-MADE FIBRES AND THEIR COMPARISONS
What is melt spinning 6
Introduction to solution spinning 12
DRY SPINNING 16
DRY-JET WET SPINNING 19
GEL SPINNING 20
ELECTROSPINNING 21
Conclusion 24
results 25
References 26
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MANUFACTURING METHODS OF MAN-MADE FIBRES AND THEIR
COMPARISONS
Man-made fibres Like plastics, man-made fibres are also made from polymers. Man-made fibres
are not the same as natural fibres, such as silk, cotton and wool. There are two types of man-
made fibres – synthetic fibres and regenerated fibres.
Regenerated fibres are made from cellulose polymers that occur naturally in plants such as
cotton, wood, hemp and flax. Materials like rayon and acetate two of the first man made fibres to
be produced were made from cellulose polymers. Here plant cellulose was taken and then made
into fibres.
Synthetic fibres are made only from polymers found in natural gas and the by-products of
petroleum. They include nylon, acrylics, polyurethane and polypropylene. Millions of tons of
these fibres are produced all over the world each year.
Spinning
Polymer that is to be converted into fibre must first be converted to a liquid or semiliquid state,
either by being dissolved in a solvent or by being heated until molten. This process frees the long
molecules from close association with one another, allowing them to move independently. The
resulting liquid is extruded through small holes in a device known as a spinnerette, emerging as
fine jets of liquid that harden to form solid rods with all the superficial characteristics of a very
long fibre, or filament. This extrusion of liquid fibre-forming polymer, followed by hardening to
form filaments, is called spinning (a term that is actually more properly used in connection with
textile manufacturing). Several spinning techniques are used in the production of man-made
fibre, including solution spinning (wet or dry), melt spinning, gel spinning (a variant on solution
spinning), and emulsion spinning (another variation of solution spinning).
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What is melt spinning?
Melt spinning is a process for producing filaments. However, only those polymers that can be
melted without undergoing thermal degradation can be spun into fibres/filaments using this
process. Some of the typical examples are nylon-6, nylon 66, poly(ethylene terephthalate) and
poly(propylene). Though, melting is the essential criteria for carrying out melt spinning, it is not
the sufficient condition. There are other requirements that a polymer should meet before it can be
regarded as spinnable. These are discussed in detail later in this section.
What are the various components of a melt spinning line?
A typical melt spinning setup consists of a melting device-normally an extruder, a manifold-
distribution arrangement for the melt, a metering pump- device to regulate polymer flow rate, a
spin-pack- arrangement to filter and extrude the polymer through fine holes, a quench duct-
cooling zone for the extruded polymer filament to turn solid, and a winder- a device to pull and
wind the solidified filament. This arrangement is shown schematically in Figure 2.1 . The entire
line from extruder output to the spin pack are maintained at a constant temperature, which is
called the spinning temperature.
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Figure 2.1: Schematic diagram of melt spinning machine
Each of these components in the spinning process has a critical function to perform, which will
become clear as the discussion continues. The polymer is taken in chip form, which is a
cylindrical form having dimensions in the range of 1-3 mm. A polymer chip is first subjected to
an extruder.
1.What is an extruder and what does it do?
In earlier days, the polymer chips were melted using heating grids, however, now, extruders have
completely replaced other melting arrangements. Even when polymer is fed to spinning section
in melted form directly from a continuous polymerization line, the extruder is often used as the
first device in the spinning line. This is because an extruder performs multiple functions. Apart
from melting solid polymer chips, an extruder homogenizes the melt by mixing it at various
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stages. Homogenization is an important aspect in order to ensure continuous spinning without
any breaks or non-uniformity in the spun yarns.
What is the design of the extruder?
In order for the extruder to carry out all these functions effectively, extruder design is very
critical. Figure 2.2 shows the schematic diagram of a typical extruder. It has a cooled feeding
zone- where the chips enter the extruder, a melting zone- where chips melt with the heat supplied
by the heaters and the heat generated by the dissipation of the polymeric viscous forces, a
compression zone- where the material is compressed into a smaller volume to push out trapped
gasses. This is followed by a metering zone, which is the narrowest part of the extruder channels.
Because of its constricted size, only a limited amount of polymer melt may be dragged through
this zone depending upon the screw rpm. Since the metering zone does not allow the entire
material coming to the compression zone to pass through, the excess polymer is pushed back
resulting in continuous mixing. At the end of the metering zone is the head of the extruder screw,
which may have spikes (optional feature) for further mixing/homogenization.
Figure 2.2 Schematic diagram of extruder
The design of extruder and its screw may vary considerably depending upon the material being
processed and the principal functions required for processing that material. The readers may refer
to other literature for details about the various extruder design and their functions.
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The design of the screw, which includes the length to diameter ratio (aspect ratio of 1:25 or
1:40), angle of the flanges, etc. is kept in accordance to the specific heat capacity and rheological
behaviour of the polymer it is meant to process. Higher the amount of heat required to be
transferred to the polymer, longer is the residence time. For example for PP, since the heat
capacity of the polymer is large and the molecular weight is often high, it needs longer residence
time in an extruder to attain lower melt viscosity. A considerable amount of heat has to be
transferred to the polymer to melt it and bring it to the temperature of spinning. Similarly, if a
polymer is to be blended with an additive, the extruder design should allow effective mixing and
homogenization, which is again the function of the residence time and the shear rate.
The design of the screw also has significant effect on the heat generated during shear melting of
the polymer, and the energy needed for melting the polymer chips is provided by both the heaters
and the mechanical action of the screw.
4.What is a metering pump?
Metering pump has a very important function in spinning as it regulates the through put of the
polymer from the spinneret. Throughput rate and the winding speed (i.e. take-up speed) together
decide the denier of the spun filament. A metering pump must deliver constant throughput
irrespective of the back pressure felt by it from the choking filters in a spin pack. Therefore, only
the positive displacement pumps are used for metering polymer melt in spinning.
Typical design of a gear type metering pump is shown in Figure 2.3. The pump has two gears
whose teeth are intermeshed with each other at the center. The gear pair sits in a cavity made into
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a metal plate and with tip of the teeth in very close clearance from the wall of the cavity. The
polymer enters from the one side of the intermeshed zone and fills the empty spaces between the
two teeth of each gear as they emerge out from the intermesh. This fluid is then taken around the
gears by their teeth as shown in the figure. When the polymer reaches the other side of the
intermesh, it is forced out of the spaces between the teeth as the teeth enter the intermesh zone.
The emptied out or pushed out fluid then exits from the other side of the intermesh to the spin
pack. The quantity of the fluid passing through the metering pump is given by the number of
teeth getting filled and emptied in a unit time.
Figure 2.3 Schematic diagram of metering pump
Mass flow rate = volume between teeth x no. of teeth in a gear x 2x rpm x density of melt
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The volume of gear pump and its efficiency of pumping may be estimated as per the description
given in the literature.
6. The spinneret- an important component
The last but also the most important of all components in the spin-pack is a spinneret plate. It is
simply a thick metal plate with fine holes drilled through them as shown in Figure 2.4. The hole
has larger diameter towards the inside surface with conical entry. This allows entry of the
polymer melt with less pressure drop. The conical entrance facilitates alignment of the molecules
to some extent to enable them to enter without much force. However, the most important
dimension in the spinneret is the length and diameter of the final cylindrical spinneret (hole).
Polymer passes through it in a shear flow and comes out on the other end as an extruded strand.
Spinneret plates for monofilaments have single spinneret hole with diameter of about 0.5-1 mm,
while those for multifilament have several holes with diameters in a range of 0.5-0.05 mm. In
case of monofilament spinning, spinneret plate with one hole, spins a single filament which is
wound on a bobbin. The deniers used for such filaments are in excess of 20. However, for multi
filament yarn, the spinneret plate has several holes arranged in a particular fashion and all the
extruded filaments from this spin-pack are wound together on one bobbin to make a multi
filament yarn. In a multi-hole spinneret plate, holes are placed is staggered configuration so as to
allow enough separation from each other and to allow cooling air to be available to all the
filaments in the quenching zone. Also, the space between the various holes allows filaments to
spin independently without sticking to each other during extrudate swell (also known as die
swell) phenomena (explained later).
The main role of a spinneret is to impart cross sectional shape to the extruded filaments. The
cross section may vary from circular to trilobal, to hexalobal or hollow, etc. Usually it is thought
that spinneret is able to orient polymer chains to make a fibre. It is not true. Spinneret is much
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bigger than the dimensions of a polymer chain, and hence, can not induce orientation in coiled
polymers.
ADVANTAGES OF MELT SPINNING :
staple and continuous filament.
– 3000 ft/min ).
DISADVANTAGES OF MELT SPINNING :
Introduction to solution spinning
Solution spinning is carried out in the following situations:
(a) Spinning polymers with very high melting point or melting point above their degradation
temperature can not be subjected to melt spinning process. Such polymers are spun into fibres
using the methods of solution spinning, which are much more complex processes than the melt
spinning.
(b) Solution spinning is also recommended for situations when high performance fibres have to
be spun. In such situations, usually the polymers used have very high molecular weight and they
can not be obtained at spinnable viscosity below their degradation temperature.
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(c) Also, in situations, when entanglement density of the spinning liquid is required to be
regulated to obtain structures that can be drawn to very high draw ratios, solution spinning comes
out to be the method of choice for making such fibres.
How is solution spinning different from melt spinning?
Solution spinning, in principle, is similar to melt spinning with the only difference that the
melting point of the polymer is depressed to below the room temperature by adding a solvent.
However, the solvent has to be eventually removed from the extruded polymer solution by either
coagulation or evaporation to allow solidification. Therefore, solution spinning involves not only
heat transfer similar to melt spinning, but also one-way or two-way mass transfer unlike melt
spinning.
What are the different types of solution spinning?
There are principally two types of solution spinning methods-
a) wet spinning and
(b) dry spinning
(c) a variation of wet spinning is dry-jet wet spinning.
In solution spinning, a polymer is dissolved in a suitable solvent and is extruded inside a
coagulation bath containing a non-solvent (immersion-jet wet spinning) or into a heated chamber
of air (dry spinning). When the polymer solution is extruded in the air but eventually taken into a
coagulation bath is known as dry-jet wet spinning. This is because, as the name suggests, the
spinning jet (spinneret) is in the dry state unlike in wet spinning, where it is immersed inside the
coagulation bath (also referred as immersion jet wet spinning). Figures 3.1-3.3 show
schematically the arrangement of spinning in all the three methods
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Figure 3.1: Schematic representation of immersion jet wet spinning method.
How is polymer solution (dope) prepared?
In solution spinning, first polymer solution, which is also called dope, is prepared by mixing
powdered polymer into a solvent. If the required quantity of high molecular weight polymer
powder is added at one go in a solvent, polymer particles swell and agglomerate to make lumps.
This makes the direct dissolution extremely difficult. Therefore, different strategies are often
employed to enable dissolution of high molecular weight polymers.
The approaches may involve
(a) dispersing the polymer particles in a solvent at a low temperature (as in the case of PAN in
DMF or DMSO). At low temperature solvating power of the solvent is low and it allows
dispersion of particles without their sticking to each other. After proper dispersion, the
temperature is slowly increased to dissolve the polymer particles.
(b) dispersing the polymer particles in a solvent-nonsolvent mixture (such as cellulose in
NMMO-water mixture). Since at these conditions, solvation power of the solvent is again very
low, the particles are easily dispersed in the solvent medium without undergoing swelling or
agglomeration. Thereafter, the dissolution is initiated, under high agitation, by increasing the
solvation power of the solvent by heating the solvent (in PAN-DMF system) or by removing
nonsolvent through evaporation (as in cellulose-NMMO-water system). This initiates dissolution
of individual particles without agglomeration, and a homogeneous dope is formed.
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(c) In some cases, the polymer has to be modified in order to make it soluble in a common
solvent. For example, to make cellulosic fibres, alkaline cellulose is xanthated (reacted with CS2
to form sodium cellulose xanthate), which is soluble in dilute aqueous NaOH solution and can be
easily spun by wet spinning process into a regeneration cum coagulation bath. In this case, the
cellulose comes out of the soluble phase and solidifies as the xanthation is reversed by a suitable
reaction in the spinning bath.
What is the basic process of solution spinning?
(i) Preconditioning of polymer dope
In a typical wet spinning line, the dope solution is filtered to remove gel particles or any solid
impurity and deaerated to remove trapped air/gasses. If necessary, the polymer dope may also be
heated to a pre-determined temperature. This ensures smooth extrusion of the polymer solution
into the spinning line. A metering pump is used similar to that in melt spinning to regulate the
flow of the polymer solution to the spinneret (Figure 3.1).
(ii) Spinneret in solution spinning
The spinneret plate, in solution spinning, is made of a soft corrosion resistant material, such as
special grade SS or platinum. It is usually thin with diameter of individual spinneret holes in the
range of 0.025 – 0.1 mm and L/D ratio of 1. Both the diameter of the spinneret and the length of
the spinneret are much smaller than those kept in melt spinning. This is because the viscosity of
the polymer solution is significantly lower (300-500 poise) and a high pressure is not required to
push the dope through the spin pack or spinneret holes. The holes are also placed very close to
each other because the elasticity of the polymer solution is much less compared to that in melt
spinning and the polymer solution shows only a limited extent of extrudate swell.
(iii) Coagulation bath in wet spinning
The polymer solution is extruded inside a coagulation bath which normally has a mixture of a
solvent and a nonsolvent. The composition of the coagulation bath, termed as “bath
concentration”, is expressed as the concentration of solvent in the solvent/nonsolvent mixture. A
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large number of filaments are extruded into a bath using a single or multiple spinnerets.
Therefore, it is important to ensure uniform coagulation conditions among the peripheral and
inside filaments. However, the filaments at the periphery readily receive ample amount of fresh
nonsolvent, while those inside tend to get limited supply with higher concentration of leached
out solvent. Attempts are made to maintain concentration of coagulation bath by constantly
removing a certain amount of spent coagulation fluid and replacing it with fresh coagulation
fluid.
Temperature is another important parameter in wet spinning. Both the temperature of extruded
fluid and that of coagulation bath are maintained separately. Usually, dope
temperature is kept higher to avoid fluid flow problems as discussed later, while the coagulation
bath temperature is kept towards low to control coagulation rate and improve cohesiveness of the
spinning line.
The coagulation fluid is allowed to flow along the filaments (co-current). This facilitates the
exchange of solvent and nonsolvent with the coagulating filament without offering excessive
fluid drag forces.
(iv) Post coagulation processes
The fibre from the coagulation bath is washed several times, stretched, crimped, and/or heat-set
(as may be required for a particular fibre) before winding it as a filament or cutting it into staple
fibres.
DRY SPINNING
In dry spinning, the polymer dope solution, after filtration and deaeration, is metered using a
metering pump and pushed through a multihole spinneret into a closed spinning chamber/tower
circulated with heated air/gas. The solvent from the extruded filaments evaporates due to the
high surrounding temperature of the gas and is carried out of the spinning chamber by the
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circulating hot gas. The solvent and the gas are separated and recycled back into the spinning
system.
The spinning chamber may be a single shell tower with heated gas circulated in either co-current
or counter-current fashion or a two shell tower, where fresh gases enters in both shells separately
and removed separately (Figure 3.3). The second design helps in faster removal of solvent from
the spinning filament as it allows higher concentration gradient of solvent to be maintained
between the partially dried filament and the heated gas surrounding the fibre. As per the Fick’s
law, the diffusion flux (amount of solvent removed due to diffusion per unit time and area) of a
diffusing species (here solvent) is proportional to its concentration gradient in a system.
The extruded filament solidifies through partial crystallization, as the solvent is removed with
spinning distance from the spinneret. The solidified filament is collected on a bobbin or guided
through a set of godets to washing baths containing nonsolvent to remove traces of the solvent
present inside the spun filaments. The filaments are subsequently drawn, dried, crimped, heat-set
and cut to staple fibres as required.
Figure 3.3: Schematic representation of dry spinning method.
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Differences in Melt spinning, Dry spinning and Wet spinning
Topics Melt spinning Dry spinning Wet spinning
Production fiber
type
Filament and staple Only filament Filament and
staple
Productivity High High Low
Investment cost Low High Low
Solvent Not required Only volatile organic solvent Both organic and
inorganic solvent
Environmental
hazard
Non toxic Toxic Toxic
Heat of spinning High Very high Low
Spinning speed 2500-3000ft/min 2500-3000ft/min 150-300ft/min
Spinneret holes 2000 300-900 20000-75000
Uses Melt spinning used
for the production
of polyester ,
nylon ,olefin ,saran,
glass fiber.
Dry spinning used for the
production of acetate ,
triacetateand some
acrylic ,modacrylic ,spandex ,
vinyon , (PVC,PVA) fibres.
Wet spinning
used for the
production of
aramid , lyocell,
PVC,
vinton(PVA),
viscose, Rayon,
spandex, acrylic,
and modacrylic
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DRY-JET WET SPINNING
Dry jet wet spinning, as has been mentioned earlier, is a modification of wet spinning, where the
spinneret is kept just outside the surface of coagulation bath. In this case, the fibre is extruded
into air/gaseous environment and then is pulled inside a coagulation bath. Mostly the baths are
deep to allow vertical movement and coagulation of extruded fibre before it touches a guide
roller (Figure 3.2). The gap between the spinneret and the coagulation bath surface, called air
gap, varies with the type of polymer and technology being used. In acrylic spinning, this gap
may be as small as a few millimeters, while in lyocell spinning, it may be up to several
centimeters.
This small difference in arrangement of spinneret (i.e. placing it outside the coagulation bath)
brings about significant difference in spinning performance and ultimate structure of the fibre. It
is often said that dry-jet wet spinning imbibes the benefits of both dry spinning and wet spinning.
However unlike dry spinning, the air gap in dry-jet wet spinning is too small to allow any
appreciable removal of solvent before the protofibres enter the coagulation bath. However, it is
still sufficient to bring about changes on the surface of the extruded filament. It is hypothesized
that in PAN spinning, a kind of dense cuticle (probably hydrophobic) is formed on the extruded
fibres as they pass through the air gap. This in turn changes the diffusion dynamics of the solvent
and nonsovent during the coagulation of the fibres.
Some of the benefits of dry-jet wet spinning are (a) high speed of spinning, (b) high
concentration of dope, (c) high degrees of jet-stretch ratios, and (d) control of coagulation
kinetics by monitoring coagulation bath parameters. Among these benefits, (a) to (c) are derived
because of the use of dry-jet and the air gap, while (d) is derived from the use of wet coagulation.
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Figure 3.2: Schematic representation of dry-jet wet spinning method.
ADVANTAGES OF DRY JET WET SPINNING :
.
DISADVANTAGES OF DRY JET WET SPINNING :
may give a colour effect.
ce in air flow can disturb the regular filament.
GEL SPINNING
The polymer is not in a true liquid state during extrusion. Not completely separated, as they
would be in a true solution, the polymer chains are bound together at various points in liquid
crystal form.
-chain forces in the resulting filaments that can significantly
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increase the tensile strength of the fibers. In addition, the liquid crystals are aligned along the
fiber axis by the shear forces during extrusion. The filaments emerge with an unusually high
degree of orientation relative to each other, further enhancing strength. The process can also be
described as dry-wet spinning, since the filaments first pass through air and then are cooled
further in a liquid bath. Some high-strength polyethylene and aramid fibers are produced by gel
spinning.
ADVANTAGES OF GEL SPINNING :
ble for liquid crystalline polymers.
DISADVANTAGES OF GEL SPINNING :
ELECTROSPINNING
force to draw charged threads
of polymer solutions or polymer melts up to fiber diameters in the order of some hundred
nanometers.
spinning of fibers.
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ocess does not require the use of coagulation chemistry or high temperatures to produce
solid threads from solution.
molecules.
precursors is also practiced; this method ensures that no solvent
can be carried over into the final product.
STEPS OF PROCESSING
charged, and electrostatic repulsion counteracts the surface tension and the droplet is stretched; at
a critical point a stream of liquid erupts from the surface. This point of eruption is known as the
Taylor cone.
m breakup does not occur ( if
it does, droplets are electrosprayed ) and a charged liquid jet is formed.
charge migrates to the surface of the fiber.
is then elongated by a whipping process caused by electrostatic repulsion initiated at
small bends in the fiber, until it is finally deposited on the grounded collector.
ds to the
formation of uniform fibers with nanometer-scale diameters
APPLICATIONS OF ELECTROSPINNING
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Conclusion
An apparatus has been developed to melt-spin ultra fine continuous filaments with only cold air
drawing. Parametric experimental studies were carried out to study the effects of processing
conditions on the resulting fiber properties. A theoretical process model was established and used
to study the fiber attenuation mechanism under cold air drawing.
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Result
Result behind this report is that for production of man made fire there is mainly three procedure
all three are different and they have diff procedure, diff, Properties of end product,different
equipment are use.
So conclusion behind this report is that the method of fibre production depend upon that which
fibre have to be produce.
Future scope of man made fibre
The origins of the man-made fiber (MMF) industry are found in the first commercial production
of artificial silk using cellulosics by De Chardonnet in France in 1802 Regrettably the business
declared bankruptcy in 1894 However, not to be discouraged, the industry continued to develop
other cellulosis and acetates until the arrival of nylon which was discovered by Wallace
Carothers at DuPont in the 1930s Hix discovery brought the first truly MMF to the market.
Initial applications including military uses during World War II and replacing silk in women's
hosiery. Nylon was followed by the ICl development ol polyester, discovered in the carty 1940s
by two British scientists working for Calico Printers