Advanced Fiber Spinning Technology

267 Pages·1994·19.138 MB·English

by  T. Nakajima (Auth.)

Advanced fiber spinning
technology
Edited by
Professor T Nakajima
President, Society of Fiber Science & Technology, Japan
English edition edited by
K Kajiwara and J E McIntyre
WOODHEAD PUBLISHING LIMITED
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English edition, first published 1994, Woodhead Publishing Limited
Reprinted 1996, 2000, 2007, 2009
Japanese edition, first published 1992, by Kobunshi Kankokai, Kyoto, Japan
© this edition (excluding figures), 1994, Society of Fiber Science & Technology
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ISBN 978-1-85573-182-0
Printed in the United Kingdom by Lightning Source UK Ltd
Contributors
S R Allen (Senior Research Associate, Advanced Fibers Systems
Business, Du Pont, Richmond, Virginia, USA)
He received his PhD in Polymer Science and Engineering at the
University of Massachusetts. He is the author of numerous polymer/
fiber-related publications and patents and was awarded the Fiber Society
Award for Distinguished Achievement in 1992.
Kaoru Ban (Senior Coordinator, Fibers and Textiles Technical Center,
Toyobo Research Institute, Toyobo Co, Ltd, Katada, Ohtsu-shi, Shiga-
ken, Japan)
He graduated from Kyoto Institute of Technology, and joined Toyobo
Co, Ltd, in 1969.
Ken-ichi Katayama (President, Takuma National College of Technology,
Takuma-cho, Mitoyo-gun, Kagawa-ken, 769-11 Japan)
He graduated from Kyoto University and joined Osaka Municipal
Technical Research Institute as a research worker in 1950. He was a
senior research worker at Asahi Chemical Industry Co. Ltd. from 1952
until 1972, and became an associate professor at Institute for Chemical
Research, Kyoto University in 1972. He was promoted to a full professor
in 1978, and then to a president of Takuma National College of
Technology in 1991.
Ei-ichi Kubo (General Manager of Non-Woven Fabrics Department,
Unitika Ltd, Uji-shi, Kozakura 23, 611 Japan)
He graduated from Kyoto Institute of Technology and joined Unitika
Ltd in 1964. He is engaged in research and development of spinning
technology and non-woven fabrics. He was awarded the Technology
Prize from the Society of Fiber Science and Technology, Japan, in 1993,
for his achievement in developing new non-woven fabrics.
viii Contributors
Masao Matsui (Retired Researcher, Kanebo Ltd, Osaka, Japan)
He graduated from Kyoto University and joined Kanebo Ltd in 1957. He
was involved in developing new synthetic fibers, bi-component conjugate
fibers, aesthetic fibers, and ultra-fine fibers at Kanebo Ltd. He was a
general manager of the Research Center for Synthetic Fibers of Kanebo
Ltd, and was invited to Kyoto Institute of Technology as a guest
professor from 1992 until 1994. He was awarded Dr. Eng. from
Kanazawa University in 1994.
Yasuhiro Murase (Director and Assistant General Manager of Fibers
Technology and Production Division, Teijin Ltd)
He graduated from Osaka University and joined Teijin Ltd in 1958. He
was engaged in process designing, construction and operation of
polyester staple fiber plant and the research and development of new
speciality polyester staple fibers (1958-81), and research into high
performance or high functional fibers at Teijin Fiber & Textile Research
Laboratories (1981-89). He was promoted to General Manager of Teijin
Fiber & Textile Research Laboratories in 1989 and then to his present
position in 1994.
Akihiko Nagai (Associate Professor, Seitoku University, Junior College,
Department of Life and Culture, Tokyo, Japan)
He graduated from Kyushu University and joined Teijin Ltd in 1968. He
has been engaged in research and development of fibers for industrial
usage at the Matsuyama and Iwakuni Plants (1968-81), and fundamental
research into high performance fiber at Teijin Fiber and Textile Research
Laboratories (1981-93). He moved to his present position in 1993.
Junyou Nakagawa (Chief Researcher, Technical Research Center,
Kuraray Co, Ltd, Kurashiki, Okayama-ken, Japan)
He graduated from the Graduate School of Hokkaido University (M.
Eng.), and joined Kuraray Co, Ltd, in 1968. He was awarded the
Technology Prize of Society of Fiber Science and Technology, Japan, in
1983. He has been engaged in the development and application of fibers
made from thermotropic liquid crystal polymers since 1985.
Yasuo Ohta (Assistant Research Coordinator, Fiber Research Labora
tory, Toyobo Research Institute, Toyobo Co, Ltd, Katada, Ohtsu-shi,
Shiga-ken, Japan)
He graduated from Kyoto University and joined Toyobo Co, Ltd, in
1984.
Miyoshi Okamoto (Managing Director, Toray Industries Inc, Ohtsu-shi,
Sonoyama 3-2-2, 520 Japan)
He graduated Nagoya Institute of Technology in 1960, and was awarded
Contributors ix
Dr. Eng. in 1989. He joined Toray in 1960 and has been Manager of
Ecsaine Research Laboratory, Manager of Speciality Fabrics Research
Laboratory, Manager of New Fiber Research Laboratory and General
Manager of Research Laboratories for Fibers and Textiles. He became a
Director of Toray Industries Inc. in 1989 and a Managing Director in
1992. He has received numerous awards including the Carothers
Memorial Medal from the Textile Institute (1993), and in 1989 Toray
did him the unique honour of founding the Okamoto Research
Laboratory to give top researchers the freedom to create the technology
of the next generation.
Katsuhiko Shimada (Manager, Toyama Plastics Plant, Mitsubishi Rayon
Co, Ltd, Toyama-ken, Japan)
He graduated from Osaka City University, received an MSc and joined
Mitsubishi Rayon Co, Ltd, in 1982. He has been engaged in development
of transparent polymers for POF.
Masaki Tsuji (Associate Professor, Institute for Chemical Research,
Kyoto University, Uji, Kyoto-fu, 611 Japan)
He graduated from Kyoto University in 1975, and was awarded Dr. Eng.
in 1981. He became a Postdoctorial Research Fellow at McGill
University in 1981, and returned to the Institute for Chemical
Research, Kyoto University in 1994. He was promoted to associate
professor in 1994.
Takashi Tsurumi (Manager, Cashmilon Plant, Asahi Chemical Industry
Co, Ltd, Samejima 2-1, Fuji-shi, 416 Japan)
He graduated from Tokyo University and joined Asahi Chemical Co Ltd,
in 1966. He was awarded Dr. Eng. from Kyushu University in 1991, and
was promoted to his present position in 1993.
Masaharu Watanabe (Plant Manager of Okazaki Plant, Unitika Ltd,
Okazaki-shi, Aichi-ken, Japan)
He graduated from Kyushu University and joined the research and
development center of Unitika Ltd at Uji in 1963. He is engaged in the
research and development of spinning technology especially in the field of
high-speed spinning and non-woven fabrics. He was promoted to his
present position in 1992.
H H Yang (Retired Research Fellow, Advanced Fibers Systems Business,
Du Pont, Richmond, Virginia USA)
He earned his PhD in chemical engineering at the University of
Michigan. He is the author of three books on high performance fibers,
is an honorary professor at the China Textile University in Shanghai,
People's Republic of China, and holds numerous polymer-related patents.
x Contributors
Hiroshi Yasuda (General Manager, Fiber Research Laboratory, Toyobo
Research Institute, Toyobo Co, Ltd, Katada, Ohtsu-shi, Shiga-ken,
Japan)
He graduated from Kyushu University and joined Toyobo Co, Ltd, in
1964.
Preface
This book covers the new developments of fiber spinning science and
technology. Much of the success of Shingosen, the newly specified
synthetic fiber which has been developed in Japan, depends upon a skilful
application of the spinning technology.
This book gives a comprehensive presentation of the techniques with
the theoretical background for an understanding of them.
I hope that this volume will be found useful for readers in many
countries and will contribute to a better understanding of the science and
technology of the field of spinning.
Toshinari Nakajima
President of The Society of Fiber Science and Technology, Japan
Introduction
Some of the most interesting developments of the last few decades in the
field of fiber manufacture have been the result of intensive study in
Japanese industry and research institutes. Features of such research are a
determination to push the technology towards its limits and a willingness
to embark rapidly on commercial exploitation of the results. An unusual
combination of intensive competition and co-operation between the
many substantial companies involved results in a rapidly evolving
technology. Consequently the rate of introduction of new processes and
products is considerably higher in Japan than in other countries.
This book was originally published in Japanese by the Society of Fiber
Science and Technology, Japan, in order to present a thorough scientific
and technological review of advances in fiber production, and is now
published in English to mark the 50th anniversary of the foundation of
the Society. The emphasis is upon developments either originated or
adopted in Japan. With the exception of a chapter about aramid fibers
contributed from Du Pont, the authors are leading Japanese academic
and industrial research workers.
In editing the translation we have tried to make it as friendly to
English-speaking readers as possible. We have, however, retained many
references to journals and patents written in Japanese, since it has seldom
been possible to identify clearly equivalent material in other languages.
K Kajiwara
Kyoto Institute of Technology
J E Mclntyre
The University of Leeds
Japanese Patents: explanatory note
Japanese patents appear in two stages, with different numbers at each
stage. The numbers consist of the year followed by a number within that
year. The years are numbered from the beginning of each Imperial era.
Showa is from 25 December 1926 and Heisei from 7 January 1989.
In this translation the two stages are termed iaid open' and
'examined', respectively. The years have been altered to the year AD,
which in nearly all cases can be converted into the Japanese year by
subtracting 25 from years up to '88 and 88 from years '89 onwards.
1
Fundamentals of spinning
Ken-ichi Katayama
Takuma National College of Technology, Takuma-cho, Japan
Masaki Tsuji
Institute for Chemical Research, Kyoto University, Japan
There are a great many subjects covered by the heading 'Fundamentals of
spinning'. In this chapter, however, we confine ourselves to a description
of the fundamentals of mathematical simulation for spinning and of new
findings on structural formation during spinning and fiber structure. This
description should be undertaken for each of the three types of spinning:
melt spinning, dry spinning and wet spinning. However, we are concerned
here mainly with melt spinning because it is the easiest for us to formulate
and accordingly its theory is the most sophisticated of the three. The
others are described only briefly with literature references to the details.
Nevertheless, the authors hope that this short treatise will help the
readers to understand other parts of this book.
1.1 Introduction
The viscose rayon method was developed towards the end of the last
century and the melt spinning method for synthetic fibers was established
in the early part of the 1930s. In the beginning of the history of spinning,
progress in spinning technique was mainly made by accumulating
empirical facts; that is to say, by repeating a set of procedures such as
setting a spinning condition and measuring the resultant properties and
structures of the spun fibers. There were few studies on physiochemical
changes and on structural formation in the spun fibers between the
spinneret and the take-up device. With the rapid advance of the synthetic
fiber industry in the 1940s, a strong need arose to understand the basics
of the spinning process in order to improve the productivity and quality
control of the fibers. Consequently, towards the end of the 1950s,
Ziabicki published a series of papers concerning melt spinning in which
the spinning process was analyzed mathematically as an engineering
problem: the papers served as a powerful incentive to researchers in this
field of study. About the middle of the 1960s, Kase and Matsuol,2
established a method for the quantitative description of the melt spinning