FIBER MANUFACTURING

CAPABILITIES

Melt Spinning
In this process, a polymer is melted and heated to a suitable viscosity for
fiber production. The melted polymer is pushed through a spinneret, which
is a type of die consisting of several small holes. Each hole produces an
individual fiber, and the number of holes on a spinneret defines the number
of fibers in the yarn. The melted polymer fibers then pass through a cooling
region and the fibers are combined to form a yarn, and a spinfinish is
applied. The yarn is then drawn using several godet rolls with very good
speed and temperature control to orient the molecules in the fibers and
eliminate voids, making the yarn stronger.

Melt spinning is the fastest fiber production system available in current

technology. Therefore, if the polymer is thermoplastic, then melt spinning
should be used for higher productivity. Most of the manmade fibers such as
polyester, polypropylene, nylon, and PGA are produced using melt
spinning.

Melt spinning technology is very advanced, and parameter control of the

process is strong. It is possible to produce shaped fibers such as circular,
triangular, and hollow fibers using melt spinning. Production of
biocomponent and tricomponent fibers is also possible using this process.

Secant Group has state-of-the-art, versatile melt spinning equipment with

very sensitive speed and temperature controls, along with several drafting
zones. Our design, development, and production capabilities include:

 High tenacity polyester fibers (>9g/den)

 A variety of yarns from 10 denier to 1000 denier, with eight to 136
filaments
 Shaped fibers to maximize the yarn performance for any device
property need
 Production of small yarn batches as low as one pound
 Biocomponent (including islands-in-the-sea fiber) and tricomponent
fibers using different polymers
 

Wet Spinning and Dry-Jet Wet Spinning

These processes are used for thermoset polymers such as acrylic, liquid
crystalline polymers (Kevlar and Nomex), and polyurethane. In wet
spinning, the polymer is dissolved in a solvent at a target concentration to
make a polymer solution with the desired viscosity. This polymer solution is
then extruded under heat (if needed) and pressured into a liquid
coagulation bath. Then fibers are combined as yarn and the yarn is drawn,
with very good controls, to orient the molecules in the fibers so that it
becomes stronger. 

Dry-jet spinning is very similar to wet spinning. However, for some

polymers, putting a spinneret into the coagulation bath does not work.
Therefore, the dissolved polymer is fed out of the spinneret on an air gap to
drive off the solvent and then goes into a coagulation bath to be solidified.

The production speed for both is very low compared to the melt spinning
process. The advantage of these processes is that the production of fiber
from mixtures of polymers and the incorporation of additives is easier. 
Another advantage is that fiber production is possible using very low
amounts of polymers (as low as 20 grams). This is important, especially for
newly discovered polymers that have only been produced under lab
conditions. Therefore, wet spinning and dry-jet wet spinning lines are more
appropriate for research use. 

Secant Group has versatile wet/dry-jet spinning equipment with three

coagulation baths, a dryer, and heater. Therefore, either process could be
applied to fiber design, development, and production. We can produce very
small amounts of fibers and yarns with different deniers and number of
fibers in the yarn. We also have the expertise to produce specialty
polymers and copolymers for the desired application.