Structure Development during the

Melt-spinning of Linear Polyethylene

Fibres
Presented by
V.Venkata Sai Kiran(2011TT10977)
B.Manoj Kumar(2011TT10907)
Experimental Synopsis
Apparatus developed for studying the structural development
during melt-spinning measures the following :
Tension in the fibre/filament being extruded
Fibre temperature
Fibre diameter
X-ray diffraction patterns
These are measured as a function of the distance of
monofilament from the spinneret.
The above mentioned spinning variables play a key role in the
crystallization kinetics and structure formation of synthetic fibres
Equipment
Equipment-components
Screw Extruder-Metering Pump-Spinneret combo
A melt spinning line has a rotating anode x-ray
generator along with WAXD accessories.
Feed roll whose velocity is established using a DC
motor and speed controller and winder
The spinning apparatus can be moved up/down.This
allows us to obtain data as a function of spinneret
distance.
Crystallinity and fibre morphology during melt-spinning
a polymer depend upon two factors :
Rheological Factors (Stretching of melt)
Non-isothermal effects (Heat transfer from filament)
Birefringence trend :
Birefringence values observed increased with spinline
tension, velocity gradient during draw-down and the
inverse of filament diameter.
Discussions
The maximum diameter shown is the
diameter at die-swell region.
From this point, the filament diameter
decreases as the filament accelerates and
reaches the take up velocity.
The velocity is low in the die-swell region.
It increases rapidly to take up velocity over a short distance.
The velocity gradient first rapidly increases and then quickly decreases to zero
as the take up velocity is reached.
The peak in Velocity gradient profile becomes narrower
with a decrease in mass flow rate.
Or increasing the take up velocity at constant mass flow
rate can thin down the filament being extruded.
At higher speeds, higher cooling rates are achieved owing
to smaller fibre diameters.
Increase in maximum velocity gradient, increases the
molecular orientation in the molten polymer.
Crystallization begins at the peak of velocity gradient
profile and this peak effects the kinetics of crystallization.

Temperature Profile
As the fibre exits the spinneret, rapid cooling is seen
until the crystallization begins.
During crystallization, energy is released and this
decreases the rate of cooling.
This can be seen from a plateau like region in the
temperature profile.
X-ray peaks are seen for the first time just before the
plateau-like region.
Minimum diameter and maximum velocity of
filament are attained at this stage(distance.)
After the draw-down zone, cooling rates are higher
because of higher surface area-volume ratio.
As seen in the graph, plateau
temperature decreases as the take-
up velocity is increased(at a
constant mass-flow rate).
This is so because, increase in take
up velocity, thins the filament down,
facilitating the heat exchange with
higher cooling rates.

Development of Crystallinity
Crystallization begins when the velocity gradient reaches its
peak and continues as the filament is taken-up by the bobbin.
60% crystallinity is attained at the onset of the temperature
plateau and it increases down the spinline.
This is because the filament temperature lies above Tg of the
fibre.
But, at very high spinning speeds, crystallization occurs at a
relatively longer distance from the spinneret and due to high
cooling rates, lower degrees of crystallinity are achieved.
Birefringence Vs Spinline Tension
Spinline Tension or stress increases either by
increasing the take up velocity or by
decreasing the mass flow rate, keeping the
other process parameter constant.
Birefringence increases steadily by increasing
spinline tension.
This is because of the stress induced
crystallization in the fibre.
Morphological Model