Abstract
Polypropylene (PP) filaments have become one of the most important industrial filaments. Fibers from advanced Ziegler-Natta and metallocene catalyst-based polypropylene have made inroads in technical textiles. High-modulus—high-tenacity PP filaments have found various uses in industrial applications on the basis of their superior properties and inert nature. The feed parameters as well as the processing variables - all have an important impact on the ultimate properties of PP filament, as has been observed by various researchers. This article critically reviews the production of high-modulus—high-tenacity PP filament along with proposed changes in microstructure leading to the superior mechanical properties. The contribution of crystallite and amorphous orientations, amorphous modulus, crystallinity, taut-tie molecules, and flaws in the shaping of mechanical properties of such filaments have been discussed. The chasm between practical and theoretical values in modulus and tenacity values are still large and a great deal of challenge involved in achieving high draw ratios. In most of the cases, high draw ratios have been achieved with single or multiple steps but with low strain rates and low processing speeds. Majority of the processes are batch processes and limits productivity.
Keywords
References
1.
1.
Ciferri, A.
and
Ward, I.M.
(eds), (1975 ). Ultra High Modulus Polymers ,
Wiley , New York
.
2.
2.
Zachariades, A.E.
and
Porter, R.S.
(1983 ). The Strength and Stiffness of Polymers ,
Marcel Dekker , New York
.
3.
3.
Ward, I.M.
(1985 ). The Preparation, Structure and Properties of Ultra
High Modulus Flexible Polymers , In: Key Polymers: Properties and
Performance, Advances in Polymer Science , pp. 1 -70 ,
Vol. 70,
Wiley Interscience , New York
.
4.
4.
Hiroyuki, T.
(1984 ). Polymer , 25 :
147
.
5.
5.
Mirabella, F Jr.
(1987 ). Jour. Polym. Sci., Part B, Polymn. Phy. ,
25 :
591
.
6.
6.
Tianbai, H.
(1986 ). Polymer , 27 :
253
.
7.
7.
Fanconi, B.
and
Rabolt, J.F.
(1985 ). J. Polym Sci., Polym. Phys. , 23 :
120
.
8.
8.
Svetec, D.G.
(1997 ). Tekstilec , 40 :
143
.
9.
9.
Ahmed, M.
(1982 ). Polypropylene Fibers - Science and Technology ,
Elsevier Scientific Publishing Company , New York
, 277 pp.
10.
10.
Ahmed, M.
(1982 ). Polypropylene Fibers - Science and Technology ,
Elsevier Scientific Publishing Company , New York
, 187 pp.
11.
11.
Kamezawa, M.
,
Yamada, K.
and
Takayanagi, M.
(1979 ). J. Appl. Polym. Sci. , 24 :
1227
.
12.
12.
Kamezawa, M.
,
Yamada, K.
and
Takayanagi, M.
(1979 ). J. Appl. Polym. Sci. , 24 :
1227
.
13.
13. Kavesh, et al. United States Patent 4,413,110, November 1, 1983.
14.
14.
Cannon, C.G.
(1982 ). Polymer , 23 :
1123
.
15.
15.
Mirabella, F.
(1987 ). J. Polym. Sci., Part B, Polym. Physics ,
25 :
591
.
16.
16.
Iijima, M.
and
Strobl, G.
(2000 ). Macromolecules , 33 :
5204
.
17.
17.
Kalay, G.
and
Bevis, M.J.
(1997 ). J. Polym. Sci. B: Polym. Phys. , 35 :
241
.
18.
18.
Lazic, B.
and
Jovanovic, R.
(1994 ). Melliand Textilber , 75 :
754
.
19.
19.
Leugering, H.J.
and
Kirsch, G.
(1973 ). Angew. Makromol. Chem. , 33 :
17
.
20.
20.
Varga, J.
and
Karger-Kocsis, J.
(1996 ). J. Polym. Sci., Part B, Polym. Phys ,
34 :
657
.
21.
21.
Moos, K.H.
and
Jungnickel, B.J.
(1985 ). Angew. Makromol. Chem. , 132 :
135
.
22.
22.
Garbarczyk, J.
and
Paukszta, D.
(1985 ). Makromol. Colloid Polym. Sci. , 263 :
985
.
23.
23.
Maiti, P.
,
Hikosaka, M.
,
Yamada, K.
,
Toda, A.
and
Gu, F.
(2000 ). Macromolecules , 33 :
9069
.
24.
24.
Wang, I.C.
,
Dobb, M.G.
and
Tomka, J.G.
(1996 ). J. Text. Inst. , 87 :
1
.
25.
25.
Jambrick, M.
and
Diacik, L.
(1964 ). Faserforsch U. Textiltech ., 15 :
590
.
26.
26.
Wang, I.C.
,
Dobb, M.G.
and
Tomka, J.G.
(1996 ). J. Text. Inst. , 87 :
1
.
27.
27.
Andreassen, E.
,
Myhre, O.L.
,
Hinrichsen, E L.
and
Grostad, K.
(1994 ). J. Appl. Polym. Sci. , 52 :
1505
.
28.
28.
Matsuo, M.
,
Sawatro, C.
,
Masayasu, I.
and
Yoneda, M.
(1985 ). Polym J. Jpn. , 17 :
1197
.
29.
29.
Wang, I.C.
,
Dobb, M.G.
and
Tomka, J.G.
(1996 ). J. Text. Inst. , 87 :
1
.
30.
30.
Jan Broda
,
Andrzej Wl/ochowicz
. (2000 ). European Polymer Journal , 36 :
1283
.
31.
31.
Gerrits, N.S.J.A.
and
Young, R.J.
(1991 ). J. Mater. Sci. , 26 :
2137
.
32.
32.
Keller, A.
(1989 ). Future Trends in Polymer Science and
Technology , 185 .
33.
33.
Purvis, J.
and
Bower, D.I.
(1976 ). J. Polym. Sci. Polym. Phys. , 14 :
1461
.
34.
34.
Adar, F.
and
Noether, H.
(1985 ). Polymer , 26 :
1935
.
35.
35.
Samuels, R.J.
(1965 ). J. Polym. Sci., Part A , 3 :
1741
.
36.
36.
Samuels, R.J.
(1968 ). J. Polym. Sci. , A-2 , 6 :
1101
.
37.
37.
Samuels, R.J.
(1968 ). J. Polym. Sci. , A-2 , 6 :
2021
.
38.
38.
Peterlin, A.
(1971 ). J. Mater. Sci. , 6 :
490
.
39.
39.
Peterlin, A.
(1975 ). Colloid Polym. Sci. , 253 :
53
.
40.
40.
Jambrick, M.
and
Diacik, L.
(1964 ). Faserforsch U. Textiltech. , 15 :
590
.
41.
41.
Gill and Benjamin
,
PP Fibers and Textiles
, In: 2nd International Conference , Plastic and
Rubber Institute , September 1979 .
42.
42.
Bowden, P.B.
and
Young, R.J.
(1974 ). J. Mater. Sci. , 9 :
2034
.
43.
43.
Lin, L.
and
Argon, A.S.
(1994 ). J. Mater. Sci. , 29 :
294
.
44.
44.
Nitta, K.-H.
and
Takayanagi, M.
(1999 ). J. Polym. Sci., B: Polym. Phys. , 37 :
357
.
45.
45.
Nitta, K.-H.
and
Takayanagi, M.
(2000 ). J. Polym. Sci., B: Polym. Phys. , 38 :
1037
.
46.
46.
Zhang, X.C.
,
Butler, M.F.
and
Cameron, R.E.
(1999 ). Polym. Int. , 48 :
1173
.
47.
47.
Aleksey Drozdov, D.
and
Christiansen, J.
(2002 ). Polymer , 43 :
4745
.
48.
48.
Wang, I.C.
,
Dobb, M.G.
and
Tomka, J.G.
(1996 ). JTI , 87 :
1
.
49.
49.
Clark, E.S.
and
Scott, L.S.
(1974 ). Polym. Eng. Sci. , 14 :
682
.
50.
50.
Taylor, W.N.
and
Clark, E.S.
(1978 ). Polym. Eng. Sci. , 18 :
518
.
51.
51.
De Candia, F.
,
Romano, G.
,
Baranov, A.O.
and
Prut, E.V.
(1992 ). J. Appl. Polym. Sci. , 46 :
1799
.
52.
52.
Kamezawa, M.
,
Yamada, K.
and
Takayanagi, M.
(1979 ). J. Appl. Polym. Sci. , 24 :
1227
.
53.
53.
Kunugi, T.
,
Taihei, Ito
,
Hadhimoto, M.
and
Ooishi, M.
(1983 ). J. Appl. Polym. Sci. , 28 :
179
.
54.
54.
Kunugi, T.
,
Kawasumi, T.
and
Ito, T.
(1990 ). J. Appl. Polym. Sci. , 40 :
2101
.
55.
55.
Suzuki, A.
,
Sugimura, T.
and
Kunugi, T.
(1997 ). Kobunshi-Ronbunshu , 54 :
351
.
56.
56.
Kamezawa, M.
,
Yamada, K.
and
Takayanagi, M.
(1979 ). J. Appl. Polym. Sci. , 24 :
1227
.
57.
57.
Sheehan, W.C.
and
Cole, T.B
, (1964 ). J. Appl. Polym. Sci. , 8 :
2359
.
58.
58.
Shaw, M.T.
(1975 ). J. Appl. Polym. Sci. , 19 :
2811
.
59.
59.
Coates, P.D.
and
Ward, I.M.
(1978 ). J. Polym. Sci., Polym. Phys. , 16 :
2031
.
60.
60.
Ziabicki, A.
(1976 ). Fundamentals of Filament Formation ,
Wiley , New York
.
61.
61.
Wang, I.C.
,
Dobb, M.G.
and
Tomka, J.G.
(1995 ). J. Text. Inst. , 86 :
383
.
62.
62.
Wang, I.C.
,
Dobb, M.G.
and
Tomka, J.G.
(1996 ). J. Text. Inst. , 87 :
3
.
63.
63.
Wang, I.C.
,
Dobb, M.G.
and
Tomka, J.G.
(1996 ). J. Text. Inst. , 87 :
1
.
64.
64.
Taylor, W.M.
and
Clark, E.S.
(1978 ). Polym. Eng. Sci. , 18 :
519
.
65.
65.
Kamezawa, M.
,
Yamada, K.
and
Takayanagi, M.
(1979 ). J. Appl. Polym. Sci. , 24 :
1227
.
66.
66.
Ward, I.M.
and
Capaccio, G.
(1974 ). Polymer , 15 :
223
.
67.
67.
Samuels, R.J.
(1974 ). Structured Polymer Properties ,
Wiley , N.York
.
68.
68.
Yamada, K.
,
Kamezawa, M.
and
Takayanagi, M.
(1981 ). J. Appl. Polym. Sci. , 26 :
49
.
69.
69.
Maiti, P.
,
Hikosaka, M.
,
Yamada, K.
,
Toda, A.
and
Gu, F.
(2000 ). Macromolecules , 33 :
9069
.
70.
70.
Labour, T.
,
Gauthier, C.
,
Seguela, R.
,
Vigier, G.
,
Bomal, Y.
and
Orange, G.
(2001 ). Polymer , 42 :
7127
.
71.
71.
Coulon, G.
,
Castelin, G.
and
G’Sell, C.
(1998 ). Polymer , 40 :
95
.
72.
72.
Kocsis, K.J.
(1996 ). Polym. Eng. Sci. , 36 :
203 -210
.
73.
73.
Elyashevich, G.K.
,
Poddibny, V.L.
and
Raab, M.
Relationship between Orientation and Crystallisation of Flexible Chain Polymers
, Plasty Kaucuk , 27 :
353 -357
.
74.
74.
Wang, I.
(1995 ). J. Text. Inst. , 86 :
383
.
75.
75.
Candia, M.
(1992 ). J. Appl. Polym. Sci. , 46 :
179
.
76.
76.
Sheehan, W.C.
(1964 ). J. Appl. Polym. Sci. , 8 :
2359
.
77.
77.
Laughner
(1988 ). J. Appl. Polym. Sci. , 36 :
899
.
78.
78.
Fakirov, S.
(ed.), (1995 ). Oriented Polymer Materials, Hüthig
& Wepf ,
Basel , Switzerland
, 394 pp.
79.
79.
Ward, I.M.
In:
Lemstra, P.J.
(ed.), Integration of Fundamental Polymer Science &
Technology , Vol. 2,
Chapman and Hall , London
, 559 pp.
80.
80. Prabir Kar (1998). Ph.D Thesis, IITD, pp. 12-18.
81.
81.
Yamada K.
,
Kamezawa, M.
and
Takayanagi, M.
(1981 ). J. Appl. Polym. Sci. , 26 :
49
.
82.
82.
Kunugi, T.
,
Taihei, Ito
,
Hadhimoto, M.
and
Ooishi, M.
(1983 ). J. Appl. Polym. Sci. , 28 :
179
.
83.
83.
Taraiya, A.K.
,
Richardson, A.K.
and
Ward, I.M.
(1987 ). J. Appl. Polym. Sci. , 33 :
2559
.
84.
84.
Mirabella, F.
(1987 ). J. Polym. Sci., Part B, Polym. Physics ,
25 :
591
.
85.
85.
Yamada, K.
,
Kamezawa, K.
and
Takayanagi, M.
(1981 ). JAPS , 26 :
49
.
86.
86.
Samuels, R.J.
(1968 ). J. Polym. Sci. , (A-2 )6 :
1101
.
87.
87.
Samuels, R.J.
(1967 ). J. Polym. Sci. , C-20 :
253
.
88.
88.
Samuels, R.J.
(1970 ). J. Macromole. Sci. , B4 :
701
.
89.
89.
Sheehan, W.C.
,
Wellman, R.E.
and
Cole, T.B.
(1964). In: Proc. Symp. of Polypropylene Fibers ,
Southern Res. Inst . Sept. 73 .
90.
90.
Taylor, W.N.
and
Clark, E.S.
(1978 ). Polym. Eng. Sci. , 18 :
518
.
91.
91.
Kamezawa, M.
,
Yamada, K.
and
Takayanagi, M.
(1979 ). J. Appl. Polym. Sci. , 24 :
1227
.
92.
92.
Kunugi, T.
,
Taihei, I.
,
Hadhimoto, M.
and
Ooishi M.
(1983 ). J. Appl. Polym. Sci. , 28 :
179
.
93.
93. Kar, P. PhD Thesis, Feb 1999, IIT Delhi.
94.
94.
Mirabella, F.
(1987 ). J. Polym. Sci., Part B, Polym. Physics ,
25 :
591
.
95.
95.
Fanconi, B.
and
Rabolt, J.F.
(1985 ). J. Polym. Sci., Polym. Phys. , 23 :
120
.
96.
96.
Ward, I.M.
and
Hadley, D.W.
(eds), (1971 ). An Introduction to Mechanical Properties of
Solid Polymers ,
John Wiley & Sons , England
.
97.
97.
Schmidt-Rohr, K.
and
Spiess, H.
(eds), (1994 ). Multidimensional Solid-State NMR and
Polymers ,
Academic Press , London
.
98.
98.
Bower
(1972 ). J. Poly. Sci: Poly. Phys . 10 .
99.
99. www.ntcresearch.org/pdf-rpts/Bref0602/M01-GT01-02.pdf
100.
100.
Kunugi, T.
,
Taihei, I.
,
Hadhimoto, M.
and
Ooishi, M.
(1983 ). J. Appl. Polym. Sci. , 28 :
179
.
101.
101.
Huda, M.N.
,
Dragaun, H.
,
Bauer, S.
,
Muschik, H.
and
Skalicky, P.
(1985 ). Colloid and Polymer Science , 263 :
730
.
102.
102.
Nadella, H.P.
,
Spruiell, J.E.
and
White, J.L.
(1978 ). J. Appl. Polym. Sci. , 22 :
3121
.
103.
103.
Gill and Benjamin
(1979).
PP Fibers and Textiles
, In: 2nd International Conference, Plastic and Rubber
Institute , September .
104.
104.
Cannon, C.G.
(1982 ). Polymer , 23 :
1123
.
105.
105.
Peterlin, A.
(1977 ). Polym. Eng. Sci. , 17 :
183
.
106.
106.
Takanagi, M.
,
Imada, K.
and
Kajiyama, T.
(1966 ). J. Polym. Sci., C , 15 :
263
.
107.
107.
Yamada, K.
,
Kamezawa, M.
and
Takayanagi, M.
(1981 ). J. Appl. Polym. Sci. , 26 :
49
.
108.
108.
Kunugi, T.
,
Taihei Ito
,
Hadhimoto, M.
and
Ooishi, M.
(1983 ). J. Appl. Polym. Sci. , 28 :
179
.
109.
109.
Cannon, C.G.
(1982 ). Polymer , 23 :
1123
.
110.
110.
Williams, J.G.
(1984 ). Fracture Mechanics of Polymers .
111.
111.
Michielsen
(1992 ). J. Mat. Sci. Let. , 11 :
982
.