What Is Polypropylene?
What Is Polypropylene?
What Is Polypropylene?
What is Polypropylene?
• Polypropylene fibers are industrially prepared by spinning from the melt by the
conventional low oriented yarn (LOY) or partially oriented yarn (POY) methods,
further by aerodynamic procedures, such as spun bonded yarn or using the
melt-blown technology.
• The mass coloration is usually connected with spinning process. During melting
of the polymer, its molecular weight decreases by about 20% on the average
without consequences for its fiber-forming properties.
• The first melt filtration of the PP occurs at the head of the extruder and the last
one at the spinning head.
Melt Flow Index
The melt flow index (MFI) or melt flow rate (MFR) is a measure for the ease of flow of melted plastics.
It is often used in the plastic industry for quality control of thermoplastics. The method is described in
the standards ASTM D1238 and ISO 1133. A small sample of about 5 grams is heated above its
melting or softening point and forced to flow through a capillary using a piston actuated by a specified
weight, usually 2.16 kg or 5 kg. The weight of melt in grams flowing through the capillary in 10 minutes
is the melt flow index.
Melt Flow Indexer
Spinning and Drawing.
• The polymer from which low molecular weight material has been dissolved out is melted, and
spun by gear pump pressure through spinnerets.
• Melt spinning is usual, partly because it is cheap, mainly because polypropylene of high D.P.
is diffcult to dissolve.
• The polymer before spinning is about 50 per cent crystalline; after having been spun, the fibre
has a 33 per cent crystalline content.
• It is stretched or drawn and this increases the crystallinity to 47 per cent; then it is annealed,
i.e., given a final heat treatment in which the higher temperature increases the mobility of
the polymer molecules and gives them an opportunity to re-arrange themselves a bit and
pack together better; this increases the crystallinity to 68 per cent.
• During the spinning the polymer becomes birefringent as would be expected from the
orientation induced by the traction of the jet, and the degree of birefringence is increased by
the drawing process, but the highest value obtained is 0.035, whereas " theoretically " it
could be 0.067.
• This discrepancy is interpreted as indicating that the molecules never open out completely
but exist in a stable helical form.
Main phases of the production process:
Metering: One or more spinning gear pumps receives the molten polymer and sends it
through the spinning pack to homogenize the product, feed the spinning pack at a constant rate,
and prevent fluctuation due to screw extruder. Polymer, in the form of pellets or granules, is fed
into an extruder, where it is melted and pumped via a positive displacement pump to the melt
spin pack.
Spinning: The spin pack consists of filters and channels that supply molten polymer to a
multifilament spinneret. The distributor distributes the molten polymer over to die surface. The
diameter of the die varies from 0.5 to 1.5 mm, depending on the denier required.
Quenching: Newly extruded molten filaments that exit the spinneret are cooled, usually by
cool air, without damaging the filaments, and solidified. The cooling zone can be as simple as a
region in which quenching air is blown across the filaments, or it may be an elaborate chamber
constructed so the cooling environment can be strictly controlled.
Finishing: In order to improve antistatic and reduce abrasion.
Hot Stretching: Process of enhancement of the physico-mechanical properties.
Crimping: Improving the bulk.
Thermosetting: Treatment in hot air or steam that removes the internal stresses and relaxes
fibers. The resultant fibers are heat-set with increased denier.
Cutting: The fibers are cut into 20 to 120 mm length, depending on whether they are intended
for cotton or woolen system.
PP has the following properties:
light weight
strong
hydrophobic
flexible
has low thermal conductivity etc.
Because of all this, it is widely used to make undergarments, jackets for outerwear,
swimming suits, filters, bags and diapers.
Some of the main PP fiber characteristics:
Polypropylene fibers are produced in a variety of types with different tenacities in order to suit varying
market requirements. Fibers for general textile uses have tenacities in the range of 4.5-6.0 g/den.
High tenacity yarns up to 9.0 g/den are produced for the use in ropes, nets and other similar
products. High performance PP fibers have been made with high strength and high modulus.
The techniques include ultra-drawing, solid state extrusion and crystal surface growth. It is possible
to make the filaments with tenacities over 13.0 g/den.
❑ Automotive industry
❑ Carpeting
❑ Packaging
❑ Fiber, filament, film, pipes
❑ Upholstery fabrics and bed covers
❑ Toys, bottle caps, disposables
❑ Hygiene
❑ Apparel
❑ Technical filters
❑ Woven bags
❑ Ropes and twins
❑ Tapes
❑ Construction fabrics
❑ Absorbent products (diapers)
❑ Furniture industry
❑ Agriculture