Professional Documents
Culture Documents
1541391651H08TM03 Qi
1541391651H08TM03 Qi
SYNTHETIC FIBRES
1. INTRODUCTION
Textile fibres both natural and manufactured have been used to make clothing for
several thousand years. Manufactured fibres are fibres produced from chemicals and can have
superior properties to natural fibres that are grown or developed from plant and animals. The
production of manufactured fibres is an example of how industrial process has contributed to
modern life. Manufactured fibres are those materials that are made by human beings by
drawing and orientation of polymers that are commonly called fibre-forming polymers. A
manufactured fibre also referred to as synthetic fibre is a chain of small units (a chemical
substance) joined together to form a large single unit called a polymer. Polymer is a Greek
word; Poly meaning many and mer meaning unit/part. Polymers were accidentally
synthesised, however as more and more applications were discovered polymers have
penetrated into all fields of applications in large volumes. Polymers may be broadly classified
as Natural and Synthetic, various other ways of classification of polymers is given in Figure
1.
Synthetic fibres are prepared from the respective monomers by a process called
polymerization. Polymerization is a chemical process that prepares and combines the
components for fibre formation. Polymers are macromolecules built up by linking-up large
number of smaller molecules called monomers. Polymerization can be accomplished by the
following ways.
1. Based on Structure,
2. Polymerization methods,
3. Response technology,
5. Catalyst
Physical
Crystalline
Paper Code and Title: H08TM Textile Manufacturing and Testing
Module Code and Name: H08TM03 – Synthetic fibres
Name of the Content Writer: Dr. B. A. Muralidhar
Semi-crystalline
Amorphous
Chemical
Linear
Branched
Cross-linked
Interpenetrating
- Atactic
- Syndiotactic
Addition
Condensation
Special
Thermoplastic
Thermosetting
Homo polymer
Copolymer - Alternating
- Random
- Block
- Graft
Paper Code and Title: H08TM Textile Manufacturing and Testing
Module Code and Name: H08TM03 – Synthetic fibres
Name of the Content Writer: Dr. B. A. Muralidhar
Composite - Polyblend
- Plastic alloy
Based on Catalyst
Ziegler-Natta Catalysed
Metallocene Catalysed
Metathesis
In natural polymers, the fibre forming substance i.e. the relevant long chain polymer
molecules, has been made by nature in a ready-made fibrous form, such as cotton, flax, wool
and silk etc.
Synthetic fibres, on the other hand, are those in which man has generated a suitable
fibrous form for him. The performance properties of synthetic fibres are determined by fibre
structure, which in turn depend on the processing techniques and physical and chemical
structure of the polymer.
Polyamide fibres
Polyester fibres
Polyolefin fibres
Polyurethane fibres
2. POLYAMIDE FIBERS
After the end of World War II, two varieties of fibre nylon 6 and nylon 66 have
established as the most important synthetic fibres.
3. Industrial applications include tyre cord, hose, conveyor belt, fishing net, twines rope,
tents reinforced plastics etc.
3. POLYESTER FIBERS
Polyester fibres are long chain, linear polymers made by the condensation reaction
between an acid and an alcohol in which the linkage occurs through the formation of ester
groups. Synthetic polyester fibres are derived by the interaction of a dibasic acid with a
dihydric alcohol. First commercial polyester were spun from polyethylene terephthalate
(PET) e.g. Terylene. Polyethylene terephthalate is made by the condensation reaction of
ethylene glycol with dimethyl terephthalate. Pet fibres are produced as tow, staple fibres,
mono and multifilament fibres generally in circular cross-section in a range of brightness and
lustre, with wide range of properties to suit the specific requirements. Polyester is a medium
Paper Code and Title: H08TM Textile Manufacturing and Testing
Module Code and Name: H08TM03 – Synthetic fibres
Name of the Content Writer: Dr. B. A. Muralidhar
weight fabric with its specific gravity about 1.38g/cm3 and it absorbs a very small amount of
moisture about 0.4%. It has good resistance to acids, dilute alkalis, oxidising and reducing
agents. Polyester fibres are smooth rod-like, having circular, trilobal or multilobal cross-
section. They show good all round elastic recovery under compression, tension and shear.
Have high modulus and are dimensionally stable, with low moisture regain, low creep.
Polyester fibres have made their way into almost every type of apparel end use
suiting’s, dress materials, floor coverings, industrial applications such as conveyor belts, fire
hose, sail cloth, ropes fillings, tyre cords, electrical insulations, sewing threads etc.
4. POLYOLEFIN FIBERS
Polyolefin are fibres manufactured by long chain polymer composed of at least 85%
by weight of propylene, ethylene or other olefin units. They are spun from polymers (or)
copolymers of olefin hydrocarbons, namely ethylene and propylene (monomers) products of
naphtha cracking. The two most important polyolefin fibres are polyethylene and
polypropylene. Olefins undergo addition polymerization
The polyethylene molecules are generally branched and the degree of branching
depends upon the conditions of polymerization. The polymerization of double bonded
ethylene proved a difficult task. However, during the World War II, the low density
polyethylene (LDPE) were developed and put to some use, nonetheless its low melting
temperature and low strength were the limitations. This paved the way for the development of
high density polyethylene employing the Ziegler-Natta catalyst. High density polyethylene
(HDPE) is by large a linear polymer, with a high degree of crystallinity (80-98%). Both types
of polyethylene may be spun into fine dinear multifilament or monofilaments in a range of
diameters in round, flat, oval cross sections. Polyethylene fibres cannot be dyed effectively
using the regular dyeing methods as such it is dope dyed. The specific gravity of low density
polyethylene is in the region of 0.92 and for the high density polyethylene it is about 0.95 to
Paper Code and Title: H08TM Textile Manufacturing and Testing
Module Code and Name: H08TM03 – Synthetic fibres
Name of the Content Writer: Dr. B. A. Muralidhar
0.96. Polyethylenes are highly resistant to acids, alkalis and to most common organic
solvents.
The properties of polyethylene are largely influenced by the spinning and subsequent
stretching. Major applications include ropes, tows, twines, nettings, upholstery, filtration
fabrics, blinds, awnings, woven sacks for packaging and bags for carrying. Low cost, non-
toxic lightness, rot resistance, flexibility, easy handling, resiliency are some of the advantages
of polyethylene.
4.2 POLYPROPYLENE
In the early 1960s, the polyolefin were regarded as fibres with immense potential
importance comparable to polyamides and polyesters. Polypropylene fibres can be melt spun
like other synthetic fibres. Polypropylene molecules consists of zig-zag three dimensional
chain structure with long chain of carbon atoms attached with methyl side groups.
Polypropylene fibres offer higher temperature resistance, high strength, stiffness and
optimum crystallinity. The spinning and processing conditions have a great influence on fibre
properties. The fibres are produced in the forms of staple fibre, tow, mono and multi filament
yarns and slit films. Polypropylene is inert to a wide range of chemicals and has excellent
resistance to acids and alkalis.
Polypropylene is the lightest fibre with its specific gravity about 0.90 g/cm3, both
polypropylene and polyethylene are lighter than water. Its applications include, blankets,
sweaters, upholstery, knitwear, conveyor belts, tyre cord, tufted carpets, fishing nets, twines,
ropes, sewing threads, woven sacks, packaging etc.
5. POLYURETHANE FIBERS
polyurethane. Linear polyurethane are polymers with an inter unit linkage of (–HN-COO-)
urethane, made by the reaction of a diisocynate with a diol or glycol. Elastomeric
polyurethane have the structural feature of block copolymer and are known by the generic
name “spandex”. In the block copolymers, the long flexible segment of the molecules are
joined by urethane linkages to the short stiffer segment. They are formed by the chain
extension reaction of low molecular weight hydroxyl-terminated polyether and a
diisocyanate. Elastomeric fibres are those which display elasticity characteristics, i.e. they
stretch to several times to their original length and will snap back quickly to recover their
original length. Segmented polyurethanes may be spun in the form of mono or multi
filaments. Its specific gravity is in the range of 1.2 to 1.25 g/cm3. Its resistance to alkalis,
solvents and common chemicals is generally good but its resistance to acids varies depending
on the type of spandex.
6. POLYVINYL DERIVATIVES
1. Acrylic fibres are manufactured from polymers comprising of at least 85% by weight of
acrylonitrile repeating units and
The poly acrylonitrile fibres were found to be strong resistant polymers, difficult to
dye. 100% PAN fibres are usually highly crystalline.
Paper Code and Title: H08TM Textile Manufacturing and Testing
Module Code and Name: H08TM03 – Synthetic fibres
Name of the Content Writer: Dr. B. A. Muralidhar
Acrylic have good photo stability and are stable in dilute alkali/ acid. They are used as
filament or spun yarns. Its specific gravity is about 1.16 to 1.18 g/cm3. Acrylic fibres are
resistant to mild acids, alkalis and most common organic solvents. Strong acids and alkalis
attack the fibres. Acrylic fibres used in making carpets, knitwear, sportswear, blankets, dress
materials, draperies, furnishings, non-woven and industrial fabrics
Modacrylic fibres have excellent resistance to acids, organic solvents and alkalis. Its
specific gravity is relatively high at 1.37 g/cm3. Its applications include pile fabrics. Knitted
goods, industrial fabrics, carpets, drapery and upholstery etc.
The development of carbon filament began as early as 1850, and in 1880 carbon
filament was patented for use in incandescent lamps. One of the popular techniques used in
carbon fibre production is the controlled oxidation of polyacrylonitrile (PAN) precursor fibre
followed by high temperature carbonization in an inert atmosphere to completely remove the
nitrogen and hydrogen atoms from the polyacrylonitrile chain leaving behind carbon fibres.
This carbonized carbon fibre is further heated at an elevated temperature of the range of 1000
to 3000oC to axially organize the crystalline structure. This final heat treatment is very
important in producing high modulus carbon fibres.
Carbon fibres are black in colour, highly inert to chemicals, solvents and oxidising
agents. They are smooth surfaced with circular cross-section and have lustre. Their density is
in the range of 1.75-1.90 g/cm3. They are characterised by high strength and stiffness.
Glass is essentially manufacture from sodium calcium silicate and other ingredients
namely magnesia, alumina, potash, soda, boric acid in different percentages. The ingredients
are charged in a furnace where they are fused at high temperature to from glass filaments
directly or formed into marbles. Glass is manufactured in a large variety of compositions, two
main types being ‘E’ and ‘C’ glass. ‘E’ glass has good electrical and high heat resistance.
Whereas ‘C’ glass has good corrosion resistance to a wide range of acids, alkalis and
chemicals.
The specific gravity of glass is about 2.54 g/cm3. Glass fibres are resistant to most
solvents, acids and alkalis. Glass is not a good conductor of heat as such used for thermal and
electrical insulation. Glass fibres are produced in continuous filament form or in the short
staple form.
Aluminium silicate fibres are manufactured by the fusion of aluminium oxide and
silicon di-oxide. These fibres are used for insulation in the temperature range of 450 to
1300oC, where the regular glass, asbestos and mineral fibres become ineffective. They are
typically produced as short or long staple fibres and have good resistance to most acids, and
dilute alkalis.
The specific gravity of aluminium silicate fibres is 2.72 g/cm3 and are predominantly
used in high temperature insulations, including electrical, thermal insulation gaskets, filters
conveyors, engine blankets joint packing in furnaces, engine silencers, gas filters, castables,
pressure vessels, fire resistant products, missiles, rockets, filtration of radioactive particles.
Paper Code and Title: H08TM Textile Manufacturing and Testing
Module Code and Name: H08TM03 – Synthetic fibres
Name of the Content Writer: Dr. B. A. Muralidhar
They are mostly used for decorative purposes in upholstery, carpets, industrial
applications, medical application, fibre reinforcement, dress materials, table linen, footwear,
vests, jackets curtains, packaging material etc.
8. Conclusion:
In this module, we have touched upon some of the most important synthetic fibres use
in the textile industry. Here we introduce the viewer’s, to synthetic fibres such as the
polyester, polyamide, polyolefin, polyethylene, polypropylene, polyurethane, poly vinyl
derivatives and other miscellaneous fibres such as the carbon fibre,aluminium silicate,glass,
and metallic fibres.The classification, developments, features, properties and applications are
briefly discussed.