A fiber or a filament (a continuous form of fiber) is the fundamental unit of textile materials. It has a unique combination of high strength (tensile, bending, torsional, or compression), high flexibility (i.e., low modulus), extensibility, and shows recoverability on deformation. Most of these properties are observed in one principal direction, which is known as the axis of the fiber. Since all textile structures from one to three dimensional (yarn, fabric, or braids, etc.) are built using this basic structural unit, these structures also possess the above unique properties.These unique properties of a fiber or a filament are the result of a microstructure (morphology) in which the majority of the polymer chains are oriented in the direction of the axis of the fiber. The more oriented the polymer molecules are in this direction, the better properties the resulting fiber/ filament is likely to have. For producing man-made fibers, the polymers (either natural or synthetic) must be unfolded and extended unidirectionally to an extremely large extent resulting in a very high aspect (length to diameter) ratio and high orientation. This is known as spinning.In spinning, a small amount of polymer ($1 g) may be elongated to over 9000 m in length while the other dimension (diameter) is only in microns. This requires precise control over the spinning process to enable such unidirectional extension in the melt form. In fiber formation, all efforts are directed at controlling the microstructure of the polymer so that the properties mentioned above are obtained with respect to the principal axis of the fiber. This is unlike other polymer processing methods such as injection molding, compression molding, extrusion, and blowing, and so on, where mostly isotropic properties are desired and only a little attention is directed toward making a controlled microstructure in terms of molecular orientation and spatial arrangement. The engineering complexity of the spinning operation is evident from the fact that, in modern spinning plants, a large amount of polymer is expected to be continuously converted (spun) into filaments with nearly no breaks.In spinning, polymer melt or solution is extruded from a fine hole and is elongated by applying a external tensile force on the extruded portion. As the polymer melt or solution is pulled, it is cooled or precipitated, respectively, to form a solid filament. This filament is then usually subjected to post-spinning operations such as drawing, which applies unidirectional stretching to the material in a semisolid form, and heat setting, which is crystallization to equilibrium. Other post-spinning processes such as texturing are simply variations of the drawing and heat setting processes to impart curvilinear shape to an otherwise straight filament. This gives physical bulk to the filaments. The process of fiber formation is complete only when both spinning and post-spinning operations are carried out.
MELT SPINNING LINEMelt spinning is a process of producing filaments from a polymer melt. Ho...