Development and application of catalyst systems of high efficiency deliver polymers which are characterised by their MFR value being in the range of 10-40 g/10min. Elaboration of extrusion conditions in relation to properties of applied polymers in order to achieve improved productivity and yarn characteristics allows recommendations for the main settings. This knowledge will be a tool for every producer in order to adapt the processing of the new products to their production lines.
By investigation of yarn processing by the institutes, an indication of the range of settings for drawing, texturisation or staple processes is given, which meet the specific polymer needs and foreseen end uses, e.g. as apparel, home, technical or automotive textiles. This has been the basis for transfer and adaptation into industrial production at SMEs. However, regarding the respective results of industrial yarn, textile and carpet production, the achievable quality was not as good as expected and only could be reached with one type of polymer type, so that there is only a limited added value to be foreseen when applying this polymer to production. For some special processes (coarse technical yarn) it was not possible to reach standard quality.
This project aims to demonstrate on principle how to produce industrially textile articles, like fabrics and carpets, of better perfommance by processing yarns on existing machinery exhibiting improved properties with respect to tenacity, resilience, abrasion resistance etc. The yarns will be based upon new types of polypropene, which are going to be manufactured by the use of metallocene catalysts. In addition to offering higher quality products made from these materials it is intended to increase productivity by means of producing at higher speeds. Regarding economic objectives being ever present towards lower costs and higher profits it will be possible on the one hand to increase sales due to the higher productivity and on the other hand to increase competitiveness due to the lower production costs and the better quality, which is produced. In order to reach the appropriate technical aims it will be necessary to adjust polymer properties to processing conditions and resulting yarn, fabric and carpet properties, and vice versa. In detail, to start with, tacticity and molecular weight of the metallocene catalysed polypropene will be varied to generate a broad range of different polymers. Processing these polymers to different yarns, extrusion temperature, processing speed (POY process) and yarn count (CF/BCF types, microfibres) will be varied. Yarn processing with respect to drawing, texturizing and production of staple fibres will be investigated by means of variation of e.g. draw ratio, drawing temperature, processing speed etc., as well as, with production of fabrics and carpets processability will be detemmined depending on production speed. Subsequently product properties resulting from these changes in processing conditions will be monitored by appropriate testing methods in order to indicate, firstly, the achievable improvements of physical textile properties, and, secondly, to indicate a range for those relevant settings, which later on can be used by every producer as a basis to adapt and optimise this new method to manufacture tailor made products to his own production lines. Finally, the overall success of this project will strongly depend on an efficient co operation and a frank communication between the participants throughout the entire project.
Funding SchemeCRS - Cooperative research contracts
4860 Upper Austria