Synthetic Fibers

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Synthetic fibers

• Synthetic textiles are made from the

fibres that comes from chemical
resources. All textile fabrics
manufactured prior to 1884 were
made of the natural fibers: wool, silk,
cotton and linen. Since the invention
of synthetic fibers many fabrics have
been manufactured entirely of these
fibers or mixed with the natural fibers.

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What is polyester

Polyester is a category of
polymers that contain the
ester functional group in
their main chain. As a
specific material, it most
commonly refers to a type
called polyethylene
terephthalate (PET).
...Polyester fiber is used as
cushioning and insulating
material in pillows,
comforters and upholstery
padding.

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Importance of polyester

• Polyester is the most used and

most preferred fibre in the
textiles industry due to its better
physical properties, lower price,
versatility, and recyclability, which
offer a completely unique set of
benefits unmatched by any other
natural or synthetic fibres.
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 Continue…..
➢Globally, the polyester fibre market accounts for around 58 per cent of the
total manmade and natural fibre market. As far as end use of polyester fibre
is concerned, it has been segmented into apparel, home furnishing,
automotive, construction, filtration, and personal care and hygiene
applications.

➢The production of apparel was around 50 per cent of the total polyester fibre
end-uses in 2016. Home furnishings constituted the second-largest end-use
sector, accounting for about 25 percent of the total global polyester volumes
produced.

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Polyester
Polyester fiber, specifically poly(ethylene
terephthalate) (PET), is the largest volume synthetic
fiber produced worldwide.
DuPont and Eastman are the two world largest
polyester producers
The reasons for the dominating success of PET fiber
are:
1. Low cost
2. Convenient process ability
3. Excellent performance
Polyester

Raw Material:

➢ Ethylene glycol
➢ Terephthalic Acid /
Dimethyl terephthalate
➢ Catalyst: Zn, Pb, Cd
Polyester chips
Manufacturing
Filament Yarn

• Polymerization
• Drying
• Melt spinning
• Drawing the fiber
• Winding
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Polymerization
• To form polyester, dimethyl terephthalate is first reacted with ethylene
glycol in the presence of a catalyst at a temperature of 302-410°F (150-
210°C).
• The resulting chemical, a monomer (single, non-repeating molecule)
alcohol, is combined with terephthalic acid and raised to a temperature of
472°F (280°C). Newly-formed polyester, which is clear and molten, is
extruded through a slot to form long ribbons.
Drying
• After the polyester emerges from polymerization, the long molten ribbons
are allowed to cool until they become brittle. The material is cut into tiny
chips and completely dried to prevent irregularities in consistency.
 Melt spinning
• Polymer chips are melted at 500-518°F
(260-270°C) to form a syrup-like
solution. The solution is put in a metal
container called a spinneret and forced
through its tiny holes, which are usually
round, but may be pentagonal or any
other shape to produce special fibers.
The number of holes in the spinneret
determines the size of the yarn, as the
emerging fibers are brought together to
form a single strand.
• At the spinning stage, other chemicals
may be added to the solution to make
the resulting material flame retardant,
antistatic, or easier to dye.
Drawing the fiber
• When polyester emerges from the spinneret, it is soft and easily
elongated up to five times its original length. This increases the
strength, tenacity, and resilience of the fiber. This time, when the
filaments dry, the fibers become solid and strong instead of brittle.
• Drawn fibers may vary greatly in diameter and length, Also, as the
fibers are drawn, they may be textured or twisted to create softer or
duller fabrics.

Winding
• After the polyester yarn is drawn, it is wound on large bobbins or
flat-wound packages, ready to be woven into material.
Polyester

Structure of Polyester fiber:

Different Structures Of Polyester
Polyester Fiber Characteristics

• Strong
• Resistant to stretching and shrinking
• Resistant to most chemicals
• Quick drying
• Crisp and resilient when wet or dry
• Wrinkle resistant
• Mildew resistant
• Abrasion resistant
• Retains heat-set pleats and crease
• Easily washed
Polyester Blends
• Polyester and Cotton
1. Resist wrinkles
2. Resist stains
3. Retain shape
Polyester Blends
• Polyester and Wool
1. Wrinkle resistance
2. Shape retention
3. Increase durability
Polyester Blends
• Polyester and Rayon
1. More durable
2. Shape retention
3. More resilience
Polyester
Properties of Textile Fibers:
Tensile strength:
Tensile strength of medium tenacity polyester filament is
80,000-100,000
High tenacity filament: 105,000-125000
Staple fibers filament: 60,000-70,000
Elongation:
High tenacity filaments have 8-11 percent elongation.
Regular tenacity filaments have 15-20 percent elongation.
Staple fiber 25-40 %
Polyester
Elastic recovery:
At 2 % strecth 97 % recovery
At 4 % stretch 90 % recovery
At 8% stretch 80 % recovery
Shrinkage:
Polyester fabrics shrink 7- 10 % in boiling water
Heat set fabrics do not shrink
Ironing temperature:
135 degree centigrade. Sticking takes place > 205
degree centigrade
Polyester
Heat setting:
Fabrics of polyester are heat set at 160-220 degree
centigrade in hot air to stabilize dimensions
Specific Gravity
Polyester has specific gravity of 1.38
Effect of Moisture
Polyester is almost hydrophobic with moisture regain
of 0.4 % at standard conditions (65% humidity and
20ºC)
Polyester
• Solubility:
It can be dissolved in trifluoro acetic acid, o-chloro
phenol and in mixture of tetrachloroethylene
Action of Cleaning Agents:
there is no chemical action of soaps, detergents and
dry cleaning agents (carbon tetrachloride,
trichloroethylene)
Action of Acids:
Weak acids do not attack even at boiling temperature.
H2SO4 degrades at high temperature
Polyester

• Action of alkalis:
Resistance to weak alkalis is good

Affinity for dyes:

Polyester is usually dyed with disperse dyes in slight
acidic conditions at high temperature (130 degree
centigrade) and pressure (30 lb/sq inch)
Polyester

Thermal Properties
Softening point 220 ̊C
Melting temperature 260 ̊C

Effect of Sunlight
Polyester fiber has high resistance to degradation
by light. After prolonged exposure it suffers a
gradual loss in strength but does not discolor.
Polyester

Electrical Properties
Polyester having very low moisture regain so it is a very good
insulator.

Insects and micro-organisms

polyester is not a source of nourishment for living creature and show
excellent resistance to insects, fungi and bacteria
Polyester

Uses:
Apparel
Every form of clothing.
• Home Furnishings
Carpets, curtains,sheets and pillowcases, wall coverings, and
upholstery.
Polyester

• Other Uses
Ropes and nets,
thread, tire cord,
automotive
upholstery, sails.
Composites made of
100% polyester
fibers are widely
used as filtration
media.
Polyester

Fiberfill applications
In Fiberfill applications polyester fibers are used inside seat cushions,
back pillows and mattresses.