Numerical Simulation and Experimental Verification of Melt-Spinning Parameters’ Effects on Multi-Leaf Hollow-Profiled Fiber Preparation

Abstract

Multi-leaf hollow-profiled fiber is a complex-shaped fiber with a hollow structure with at least three leaves arranged outside. In this work, spinning processes for the preparation of multi-leaf hollow-profiled fiber with complex cross-section patterns were proposed. Initially, the characteristics and preparation methods of multi-leaf hollow-profiled fibers were analyzed, and the key technologies for their preparation were studied. Further, micro-hole spinnerets were designed, and the numerical simulations of melt flow in the spinning channel were performed. Then, the preparation of six-leaf hollow profiled fibers was carried out to study the formation of the cross-sections. Finally, as an extension and application, an experimental verification of the melt spinning parameters’ effects on eight-leaf hollow fiber preparation was conducted. From the results of the spinning experiments, it was found that when the volume flow rate of a single hole increased from 2.33 × 10−8 m3/s to 3.33 × 10−8 m3/s, the profile degree of the spun fiber increased from 30.93% to a maximum value of 40.99%. Furthermore, when the cooling speed increased from 0.6 m/s to 1 m/s, the profile degree increased from 29.56% to 41.63%. When the initial blowing height increased from 80 mm to 140 mm, the profile degree decreased from 40.99% to 27.13%. When the spinning temperature increased from 285 °C to 290 °C, the profile degree decreased from 40.99% to 38.56%. However, the winding speed had an insignificant effect on the cross-sectional shape of the spun fibers. Moreover, the spun fibers showed good performance and a natural three-dimensional crimp function.