Macromolecular structure development of dry-spinning UHMWPE fibers through the industrial high-ratio hot-drawing process

Abstract

Ultra-high molecular weight polyethylene (UHMWPE) and its decalin suspension were subjected to several industrial processes including swelling, dissolving, spinning, drying, and multi-stage high-ratio hot drawing to fabricate UHMWPE fibers (UPE fibers). The morphologies and architectures of the UPE fibers at different drawing stages were characterized by polarizing optical microscope (POM), scanning electron microscope (SEM) and atomic force microscopy (AFM). The aggregation structure evolution of UHMWPE macromolecules during the high-ratio hot-drawing process was studied by differential scanning calorimeter (DSC), wide-angle X-ray diffraction (WAXD), small angle X-ray scattering (SAXS) and other testing methods. The experimental results demonstrated that the UHMWPE/decalin spinning suspension was extruded from the spinneret hole to form a fine spinning flow, followed by the formation of the transitional-state fibers at different processing stages, and finally the ready-made fibers. The total drafting ratio of the UPE fibers after fabrication reached more than 600 times. The diameter of the single UPE filament was reduced to 5.66 μm with elevated drawing ratios. The crystal structure of the prepared UPE fibers was progressively improved, and the folding-chain crystals of fibers gradually transformed into extended-chain crystals. The mechanical properties of the UPE fibers were significantly improved. The fracture strength of the as-spun UPE fibers reaches 48.1 cN/dtex, which endows the fibers with specific characteristics such as ultra-fine denier and ultra-high strength.