1/9/2011

IInd Semester 2010-2011

TTL212
Manufactured Fibre Technology

Course Coordinator:
Dr. Bhanu Nandan
TX114A, Department of Textile Technology
Phone (O): 2659 6679
E-mail: nandan@textile.iitd.ac.in
Web: http://web.iitd.ac.in/~nandan/

Lectures on:
Monday, Thursday at TX120 (0930 – 1050 hrs)

W d
Wednesday
d att TX120 (1100 – 1150 h
hrs))

No Tutorials

Office Hours:

Weekdays (1200 – 1300 hrs and 1700 – 1800 hrs)

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Pre-requisites

Essential (TTN110)

Desirable:
Basic knowledge of textile fibres and polymer
science

Course Contents
1. Polymerization of important fibre forming polymers would include important
reactions and their kinetic rate equations. Batch versus continuous reactors for
polymerization of (~12 lectures)
• Nylon 6, Nylon 66, Poly(ethylene terephthalate), polyacrylonitrile, Modification
of PET and Nylons
2. Fundamental of Spinning (~8 lectures)

• Introduction to spinning and thermodynamics of spinning.

• Polymer rheology including shear flow through a capillary and elongational
flow in a Spinning line.
• Melt instabilities.
• Momentum and heat transport in spinning.
3. Melt Spinning (~9 lectures)

• Melt spinning lines.

• Slow speed spinning.
• Stress induced crystallization in high speed melt spinning.
• Characteristic features of PET, polyamide and polypropylene melt- spinning.
• Spin finish and its components.

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Course Contents
4. Solution Spinning (~6 lectures)

• Wet and dry solution spinning processes.

• Fundamentals of solution spinning- transport phenomena, kinetics and
thermodynamics
y includingg the effect of p
parameters on fibre structure.
• Importance of dry jet wet spinning of PAN.
5. Post-Spinning Operations (~7 lectures)

• Introduction to drawing.
• Effect of various parameters.
• Stability of drawing process.
• Introduction to heat setting in thermoplastic fibres.
• Effect
Eff t off various
i parameters
t on structure
t t and
d properties
ti off fibres.
fib

Recommended Books
References

ƒ Manufactured Fibre Technology, Editors: V. B. Gupta and V. K.

Kothari (Use it as a Textbook)

ƒ Handbook of Fiber Chemistry, Editors: M. Lewis and E. M. Pearce

ƒ Polyesters and Polyamides, Editors: B. L. Deopura, M. Joshi et al
ƒ Advanced Fiber Spinning Technology by T. Takajima
ƒ Fundamentals of Fibre Formation: The Science of Fibre Spinning
and Drawing by A. Ziabicki

Lecture handouts will be distributed via course group

mail after each lecture!!!

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Tentative Grading Scheme

Majors: 40%
Minors: 25 + 25%
Surprise Quizzes (n, where n > 3) : 10% (best of n-1)
Note: All surprise quizzes will be held at the beginning of
the lecture.

In case of absentia, you will be allowed to re-take the

((minors and majors j only)
y) only
y if y you have a medical
certificate from the Institute Hospital.

‘A’ Grade only if > 80%

‘E’ Grade if < 30%
‘F’ Grade if < 20%

Attendance Rule
Very Important !!

A student having attendance less than

75% will get one grade lower than the
actual grade earned by him/her.

You can enter anytime in the class during the lecture,

but remember, attendance will be taken at the beginning
of the lecture!

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Welcome again to the world

of polymers and fibres!!!

Textile Fibres
Definition
Hair like materials, having length more than thousand
times their diameter,
diameter capable of being converted into
yarns and fabrics.
Generally have following further characteristics:
• Strength
• Flexibility
• Elasticity
• Moisture absorption and transmission
• Dyebility
* Yarn generally is a long continuous length of
interlocked fibres

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Fibre Classification
Fibres

Natural Man-Made (Manufactured)

Natural Synthetic Inorganic

(Regenerated) Polyamide Glass
Polyesters Ceramic
Cellulose Metallic
Plants Animal Mineral Polyacrylonitrile
Protein
Polyolefins
Polyvinyl derivatives

Asbestos

Bast leaf Seed Hair Secreted

protein
t i
Flax Abaca Cotton Wool Silk
Jute Pineapple Kapok
Banana Coir

Natural Vs. Synthetic Fibres: Microscopic Observations

Cotton fibre

Longitudinal
Cross-sectional view
view

Structure of a natural fibre is

determined by the way nature
allows it to form

Synthetic fibre

Cross-sectional
Longitudinal view
view

Structure of a synthetic fibre is

determined by the spinnerets
used.

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Basic Structural Unit in Fibres

Whether it is natural or man-made,
generally all fibres are made from similar
basic structural units

Polymers

The chemical and physical structure of the polymer mostly

determines the properties of the fibres.

Hence, understanding what polymers are and their structure is

crucial.

Polymers
ƒ Long chain molecules that consists
of many colvalently linked repeating
unit.
ƒ Extraordinary range of properties

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Interesting Web Links for Polymers

1. Macrogalleria
http://www.pslc.ws/macrog.htm

2. Strange matter
http://www.strangematterexhibit.com/

How Big are Polymers

Check out the chain of beads on the right.
Imagine each bead is an ethylene unit;

In this case there are only 200 ethylene

units in this chain, its molecular weight is
5,600 (= 28 Х 200)

Molecular weight could be as high as millions!!

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Polymer Architectures

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Molecular Weight
A given mass of polymer generally has a distribution of
molecular weight. Hence, concept of “average molecular
weight” is generally used in polymer science.

Number average molecular weight

Mn = ΣNiMi/ ΣNi

Weight average molecular weight

Mw = ΣNiMi2/ ΣNiMi

Mw/Mn > 1 (Polydispersity Index)

Nobel Laureates in Polymer Science: Chemistry

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Nobel Laureates in Polymer Science: Chemistry

For Metathesis Polymerization

Nobel Laureates in Polymer Science: Physics

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Polymerization = Reaction to convert monomers

to a polymer.

From small molecules to polymers!

There are two major classes of polymer formation

mechanisms

Chain polymerization (Old: Addition Polymerization): The polymer

grows by sequential addition of monomers to a reactive site

• Chain g
growth is linear
• Maximum molecular weight is obtained early in the reaction

Step-Growth polymerization (Old: Condensation Polymerization):

Monomers react together to make small oligomers. Small oligomers
make bigger ones, and big oligomers react to give polymers.

• Chain growth is exponential

• Maximum molecular weight is obtained late in the reaction

Both classes of reaction can lead to the formation of either linear

polymers or polymer networks. Whether the linear chains or polymer
networks are obtained only depends on the number of reactive entities
per monomer.

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Step-Growth Polymerization

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Nylon 6,6

Detailed synthesis procedures in coming lectures

Polyesters

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Polyurethanes

An example of a reaction between bifunctional

molecules that does not involve the splitting out of a
small molecule at all can be found in the synthesis of
polyurethanes.

Polcarbonates

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Phenol-Formaldehyde

Chain Polymerization

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Active Sites

Free Radical Chain Polymerization

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Free Radical Polymerization:

Termination

Free Radical Polymerization:

Chain Transfer

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Monomers for Free Radical Polymerization

Anionic Polymerization: Initiation

and Propagation

Initiation

Propagation

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Anionic Polymerization: Chain

Transfer to Solvent

If a solvent that is able to

release a proton is used it can
react with the active site.
Ammonia is an example of such
a protic solvent and the reaction
results in the formation of a
negatively charged NH2 ion,
which can initiate the
polymerization of a new chain.
chain In
other words, we have chain
transfer to solvent.

Anionic Living Polymerization

Let’s consider the polymerization

of styrene initiated by metallic
sodium in an “inert” solvent in
which there are no contaminants
(i.e. there are no molecules with
active hydrogens around).

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Anionic Living Polymerization

Then if there is nothing for the anion to
react with, there is no termination
(combination with the counterion
occurs in only a few instances; the ions
hang around one another and their
attractions are mediated by solvent)
Thi allows
This ll the
h synthesis
h i off block
bl k
copolymers. Because the active site
stays alive, one can first polymerize
styrene,for example:

Anionic Living Polymerization

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Cationic Polymerization

Cationic polymerizations can be

initiated by protonic acids or Lewis
acids (the latter sometimes combined
with certain halogens).

Cationic Polymerization:
Termination and Chain Transfer
Unlike anionic polymerization, termination
can occur by anion - cation recombination,
for example, as illustrated opposite. Lots
of other side reactions can occur, with
t
trace amounts
t off water,
t as illustrated
ill t t d
below, chain transfer to monomer, and so
on. This makes it much more difficult to
make a living polymer using cationic
polymerization.

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Polymerization Techniques

Suspension Polymerization

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Emulsion Polymerization

Nylon Fibre/Rope by
Interfacial Polymerization

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