ICH 401 – LECTURE 5

FIBRES AND ELASTOMERS

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POLYMER PROCESSING FOR TEXTILE FIBRE
*A fibre is a polymeric substance whose length is at least 100 times its diameter.
*Synthetic fibres can be made to any desired ratio of length: diameter ratio.
*Natural Fibres such as cotton and wool have 1000 – 3000 length times their diameters.
Characteristics of synthetic polymers suitable for textile material:
a. High softening point to allow ironing
b. High TS over a fairly wide temperature range
c. Solubility or meltability for spinning
d. High modulus or stiffness
Some textile terms.
Staple- short lengths cat from the long continuous of element
Denier – wt(g) of 9000m of the fibre – a short of measure of the density

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Tenacity – TS per size number i.e. weight per unit length
Creep – Permanent dimensional change with continuous application of stress
Moisture content - % of moisture absorbed by fibre over the original (initial) wt under
standard condition (65% Rif and 700F)
Moisture regain - % of moisture present over wt at oven dry wt (1100C)
Crimp – A measure of difference between length of unstraightened and straightened fibre.
*For desirable textile fibre properties there must be good number of polar group relative
to the hydrocarbon groups to attain high degrees of crystallinity and the subsequent
orientation of the crystallites.
*Generally, non -crystalline (amorphous) polymers do not make useful fibres.

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*Branching disfavors fibre properties due to reduction of crystallite formation and hence
Tm and stiffness.
*Cross links if few in number, after fibre production yields greater interchain connection
and stronger fibre formed e.g. polythene, polyvinyl alcohol and protein fibres can be cross-
linked to give higher m.pt, lower solubility and moisture regain.

Polymer spinning fibres

i.Melt spinning- no solvent involved
ii.Dry spinning - evaporation of solvent
iii.Wet spinning -removal of solvent by adding a polymer non-solvent to the solution of the
polymer. The non-solvent for the polymer mixes well with the solvent of the polymer to
displace or precipitate out the polymer.

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[S+P] +NS = [S+NS] +P. S=solvent, P=polymer, NS=non-solvent

(i) Differentiate, with two examples in each case, between melt, dry and wet
spinning processes?

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Melt Spinning
*Polymer melted to molten polymer [MP]
*MP is pumped at a constant rate under high pressure through a stainless steel plate
called spinneret. This contains a large number of small holes equivalent to the no of fibre
filaments. The diameter of each hole depends on the diameter of the required fibre
filament.
*Liquid-polymer emerges through the lower side of the spinneret into air
* Solidification followed by collection together to form thread and wound up on bobbin.
*Heat of solidification does not affect heat transfer during this form of spinning.
* Drawing orients fibres during which the crystallites become more aligned toward the
longitudinal axis of drawing and give rise to optimum physical /tensile properties e.g.
tensile strength and elongation (flexibility) are increased.
*Drawing process is generally exothermic
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Melt Spinning Process
Examples of fibre-forming polymers by melt spinning include polyamides e.g.Nylons,
polyesters, polyolefins e.g.polythene, polypropylene.
Dry spinning
*Evaporation of volatile solvent e.g. acetone from the polymer solution into air or an inert
gas atmosphere
*The polymer solution is usually filtered before dry spinning
*spinning is done in a vertical tubular cells which are jacketed for temperature control in
which air, steam, inert gas is allowed in or out as required ,
*The evaporation is influenced by the heat of evaporation of the solvent.
*Downward spinning is preferably used for small denier fibre. This is to be able to control
drawing process better by the elimination of the effect of gravity
*Upward spinning is for high denier
Dry spinning is used for spinning cellulose acetate (acetone solvent) several vinyl fibres
including PVC and it's copolymers, PAN e.g. orlon from organic solvents.
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Wet spinning
*Solution of the polymer is spun through the spinneret into a liquid (non-solvent for the
poly) which coagulate or precipitate the polymer
*The major feature of wet spinning is the transfer of the mass of the polymer from the
polymer by the coagulating solvent
*Cylindrically shaped filaments are produced due to the high surface tension forces around
the filament.
*Highly concentrated viscous solutions are easier to wet spun. However to avoid a
situation whereby the polymer cannot be filtered as it is required before spinning,,
pumped or extruded, elevated temperatures that will reduce the viscosity are employed.
*High temps promote crystallization and lead to denser and stronger fibres.
*This cellulose fibres may be spun at 50°C, PAN fibres at 160-185°C.
*Wet spun yarn is usually collected in a centrifugal pot. The pot is spun on it's axis as the
yarn is introduced through a funnel
E.g. of polymers that can e produced by wet spinning include viscose, cellulose, PAN spun
from salt solution, acrylic. rayon, aramid, modacrylic and spandex. 10
ACRYLICS

Only the Sohio process 3 is in commercial use.

Polyacrylonitrile
*Polyacrylonitrile(PAN)(-CH2CHCN-)n is a very important constituent of many industrial
textile fibres existing as in many copolymers. 11
*Orlon is a commercial product made by polymerizing pure acrylonitrile.
*It is an ivory-white polymer, spun dry by dissolving it in dimethylformamide (DMF)and
any other suitable organic solvents e.g. dimethoxyacetamide(CH3CON(OCH3)2 and
tetramethylene cyclic sulphone as well as in concentrated aqueous solutions of some
salts, such as LiBr or sodium sulphocyanide(NaSCN).
*The solutionis filtered and then dry-spun.
*Acrylics, like polyester, are drawn at elevated temperatures in special machine.
*The fibers can be stretched three to eight times their original length which orients the
molecules into long parallel chains for final strength.
Properties.
*The staple fiber has esthetic properties.
*Resistance to chemical attack and especially to weathering, makes them highly useful in
several fields.
*Other acrylics, like Acrilan and Creshian are spun wet into a coagulating bath.

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Uses
*The end uses of acrylic fibers include sweaters, women’s coats, men's winter suiting, carpets,
and blankets.
* Acrylics are also suitable for pile fabrics and filter cloth.
MODACRYLIC FIBERS (Modified acrylics)
*They are synthetic fibers in which the fiber forming substance is any long-chain synthetic
polymer composed of less than 85% but at least 35% by weight of acrylonitrile units.
*Dynel is the name for staple copolymer modacrylic fiber made from a resin of acrylonitrile
and vinyl chloride.
*Write the equation for production of dynel.
*The resin is converted into staple in continuous wet-spinning process. The white resin
powder is dissolved in acetone, filtered, and run through a spinneret, where the fibers are
formed in an aqueous spinning bath. The fiber is dried, cut, and crimped.
Uses
* It is used for work clothing, water-softener bags, dye nets, filter cloth, sweaters, draperies
pile fabrics. 13
VINYLS AN) VINYLIDINES
*Saran is the copolymer of vinyl chloride and vinylidene chloride. It is prepared by mixing
the two monomers with a catalyst and heating. Colour is added by introducing the pigment
into the mass. The copolymer is melt spun by heaing and extruded at 1800 C, air-cooled, and
stretched. Uses
*Saran is resistant to attack by mildew, bacteria which makes it suitable for insect screens.
* Its chemical resistance makes it advantageous for filter-cloth applications.
*Its widest use has been for automobile seat covers and upholstery. Much film is made
from Saran.
Vinyon
*It is the trade name given to copolymers of 90% vinyl chloride and 10% vinyl acetate.
*Write the equation for the production of vinyon.
*The copolymer is dissolved in acetone to 22% solids.
*Solution is filtered, and the fibres extruded by dry-spinning technique.
*After standing, the fibers are wet-twisted and stretched.
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Uses
*Resistance to acids and alkalies, sunlight, and aging makes Vinyon useful in heat-sealing
fabrics, work clothing, filter cloths, and other related applications.

SPANDEX
Spandex is a manufactured fiber in which the fiber-forming substance is a long chain synthetic
polymer comprising at least 85% of a segmented polyurethane Trade examples of these are
Lycra, Glospan, and Numa fibers. Lycra spandex fiber results from the following reaction:

* This gives the final polymer, which is converted into fibers by dry spinning.

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*The finished composite fiber is “one of tangled disorder," and, when stretched, the chains
become oriented but exhibit a spontaneous return to the disordered state upon release of the
force.
Uses
*This fiber is used in foundation garments, hose, swimwear, surgical hose, and other elastic
products, sometimes in conjunction with other fibers, such as acrylic, polyester, acetate, rayon,
or natural fibers, which are wrapped around a core of the elastic spandex fiber.

POLYOLEFINS
Poly olefin fibers and films are represented by polyethylene film, widely used as a wrap.
*Polyethylene film is extensively exploited as a heat- and water-saving mulch for cotton,
strawberries, melons, and vegetables.
*Weed control is also claimed.
* PP fibres have excelled in special cases, such as ropes, laundry nets, carpets, blankets, and
backing for tufted carpets. 16
Fluorocarbons
Polytetrafluoroethylene (C2F4)n) as fiber or film is nonflammable and highly resistant to
oxidation and the action of chemicals, e.g. strong acids and alkalies. It retains these useful
properties from >450oF(232 oC) to 5500F(288oC)
*It is strong and tough.
*A very important property is its low friction, leading, with its chemical inertness, to wide
use in pump packings and shaft bearings.
*It is spun by carrier, extrusion and membrane, spinning technique. It cannot be made into
melt or spinning solution.

Elastomers
They can be described as amorphous polymers which is above its Tg, and contains crosslinks
to prevent slipping of chain (creep). Elastomer is a general name
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given to synthetic polymers with rubber-like elasticity which is a state in which a
polymeric material is capable of undergoing very great recoverable deformations that
occur under the influence of very smell loads.
Table below indicates some properties that have been used to describe elastomers.

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Typical properties of Elastomer.

Elastomer type Tensile strength (103 psi) Elongation (%)

Natural rubber (NR) 210 700

SB rubber 28 800
Acrylonitrile-butadiene rubber 42 600
(NBR)

Thiokol (Polysulphide) 21 300

Neoprene 245 800

Butyl rubber 210 1000
Polyurethane elastomer 350 600

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Table 2: Upper and lower use Temperatures of typical elastomer

Use temperature limit

Elastomer Upper Lower
Natural rubber (Polyisoprene) 80 -50
SBR (Butadiene – co – styrene (25%)) 110 -50

Nitrile rubber (butadiene – co – acrylonitrile (25%)) 120 -50

Butyl rubber (isobutylene – co – isoprene (5% )) 100 -40

Fluorinated rubbers 230 -50

Thiokol 80 -50
Neoprene (Polychloroprene) 100 -50
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Thus, the molecular requirements of elastomer are as follows
a. The material must be a high polymer
b. It must be above its glass transition temperature, Tg to obtain high local segment
mobility
c. It must be amorphous in its stable (unstretched state.
d. It must contain a network of crossed-links to restrain mobility (shipping) of chains.

DIAGRAM

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