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Preparation of a Novel Cellular Fiber: Control of Cell Density of the Fiber

Abstract A new cellular fiber was obtained by a post-treatment of spun fibers. Cellular polymers such as poly(ethylene terephthalate) show great promise for different engineering applications due to their high density property. Recent study has shown that some high density cellular polymers possess long fatigue life and/or equivalent strengths as compared with commercial-type neat polymers. However, only few studies have focused on the process of cellular polymer fibers to date. In this paper, the effect on a cellular structure of cellular PET fibers (hereafter called “CPET fibers”) subjected to different forming processes is discussed. An ultra saturating gas method was used to fabricate the CPET fibers with different cell densities. Inert gas nitrogen (N2) was saturated in PET fiber at high pressure to form a polymer/gas system. A pressure vessel was then discharged and polymer/gas solutions were foamed at a temperature controlled medium. The effect on the fiber’s cellular structure, particularly on the fiber cell density with different processing parameters such as pressure, saturation time, foaming temperature and time was investigated in detail. Experimental results showed that the cell density of the CPET fibers increased with increasing the pressure, saturation time, foaming temperature and time. The saturation time and pressure are key factors that affect the density of cells formed inside the CPET fibers. The foaming time however showed no substantial influence on the cell density of the fibers when held longer than 10s.