Spinning machine for bi-component fibres goes into service

Fibres made from two components – for increased functionality

Jun 30, 2004 | MARTINA PETER

A melt spinning machine which produces functional fibres from two thermoplastics recently went into operation at Empa. This allows the development of products with totally new, customized properties.

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Interested guests at the inauguration of the spinning machine for bi-component fibres in St. Gallen
 

The spinning machine for bi-component fibres was commissioned at the beginning of June and is a pilot system intended for research and development work. It will be used by Empa not only for its own research programmes, but also for joint projects with partners from industry and science. An interesting aspect of this system is its size. While pure research uses just a few grams of plastic, industrial-scale operations involve many thousands of tonnes. The research system, which is installed at Empa’s St. Gallen facility and was built by the German company Fourné Polymertechnik GmbH, is designed for quantities of a few kilograms. This produces results that can be extrapolated up to an industrial scale while still only using a small amount of material. The numerous representatives of Swiss and foreign industry who attended the inauguration event on 9 June showed great interest in the many different possibilities opened up by the system.

 

 

 
The liquid polymer is forced through the spinning nozzles at temperatures up to 300 °C and a pressure of up to 100 bar. In this way a large number of bi-component fibres can be spun and processed simultaneously.
 

Spider produces fibres with customized properties

Spider (Spinning - development – research) as the plant has been dubbed at Empa produces fibres consisting of two different plastics. The fibres can be laid side by side or arranged in a core/cladding structure and may be round, square, filled or hollow. Bi-component fibres of this type are common today in the textile industry. The most frequently used plastics are the four thermoplastic polymers polyamide (PA), polyester (PET), polyethylene (PE) and polypropylene (PP).

 

However, less common thermoplastic base materials (for example bioengineered plastics or “bioplastics”) can also be used. There are a host of potential combinations that have yet to be explored. With Spider fibres can not only be produced on a laboratory scale, their composition and formulation can be constantly varied with relatively little time and effort, something which cannot be cost-effectively achieved in industrial plants. The numerous characterization options open to Empa mean that the properties of these new fibre types can be scientifically predicted.

Special techniques such as plasma coating make it possible to construct complex fibre structures and to undertake selective chemical modifications on the fibre surface. In this way the chemical and physical properties of the fibres can be influenced as required, for instance their hydrophilic properties, strength, shrinkage characteristics and elasticity. It is also possible to incorporate nanoparticles in the cladding region to achieve a desired functionality.

New prospects for bi-component fibres

The object of this research is to identify fibres with specific properties for use in functional or “intelligent” textile materials for clothing, technical and medical textiles or fibre composites. Possible functions of these innovative textiles include the controlled release of drugs in medical plasters, shock absorbers in protective clothing, temperature control in firemen’s suits or sportswear and applications in sensor technology (for instance changing colour to indicate environmental changes). Materials can thus be tailored to make them biocompatible, biologically degradable, moisture-repellent or extra absorbent, flame-retardant or odour-reducing as needs demand.

One particularly promising avenue is the application of high-grade polymers in the form of a coating on a core made of standard polymer with resultant savings in raw materials and costs.

Another idea with great potential is to manufacture fibres with photovoltaic properties. These could convert the energy of light into electric current, turning a suit into a power plant as it were. It’s good to know that Empa’s new spinning machine for bi-component fibres is playing a part in this.

 
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1. Cladding extruder EX13-25D 2. Core extruder EX18-25D 3. Spinning pumps 4. Spinning packet 5. Monomer suction device 6. Blowing shaft 7. Air supply (water-cooled) 8. Spin finish pin 9. 1st godet (heated) 10. 1st stretching zone 11. 2nd godet (heated) 12. 2nd stretching zone 13. 3rd godet (heated) 14. Winder
 

Construction of the machine
The machine consists essentially of two thermoplastic extruders that melt and homogenize the polymer granules. Pumps ensure exact proportioning of the plastic and determine the fineness of the fibres according to the haul-off and winding speed. The spinneret, a plate with a specific number of holes of defined cross section, dictates the number of filaments and their diameter. The solidification and cooling process is controlled by the air stream in the blowing shaft. The draw take-up machine enables the fibres to be drawn and heat-treated, thereby allowing their mechanical properties to be specifically adjusted.

 

Contacts

Dr. Jörn Lübben, tel. 071 274 72 94,

Marcel Halbeisen, tel. 071 274 78 67,

 

Editorial

Rémy Nideröst,