Improvement of polyethylene fiber wettability and mechanical properties through an environmentally sustainable spinning process

Owing to its simple chain backbone and non-polar structure, polyethylene-based materials exhibit weak adhesion properties in both reinforcement and matrix form. Therefore, development of efficient production strategy is needed for polyethylene fibers with improved wettability and performance. Here, a novel single step modified melt spinning line (MMS) is investigated to obtain linear low-density (LLDPE) and medium density polyethylene (MDPE) fibers with high strength and improved wettability performance. The proposed cost-effective modified spinning system referred as MMS is able to manipulate fiber properties by using non-oily/non-toxic liquid baths, which are located between the melt spinneret and godets, during fiber spinning stage. The aim of this study is to examine the wetting behavior and mechanical properties of melt-spun PE fibers using non-oily/non-toxic liquid baths containing an organic additive. It is observed that higher drag force and interaction between fiber surface and non-oily/non-toxic liquid as ecological spinning liquid with higher dynamic viscosities provided enhanced mechanical properties of the fibers. Increasing the drag force to 0.138 N, resultant fibers exhibited modulus values of about 1 GPa and 1.3 GPa for MDPE and LLDPE, respectively at only 750 m/min take-up speed. Moreover, Arabic Gum (AG) as an organic additive into the liquid enhanced fiber wettability, i.e., water contact angle of 37.8° for MDPE samples. This versatile simple and ecological modified production line is capable of improving hydrophilicity and performance of PE fibers and can facilitate widespread use in composites for medical to defense applications at low manufacturing cost.