Natural Mineral

Fiber
 ASBESTOS
• Asbestos is the only mineral matter used as a
textile fiber in the form in which it is obtained
from natural sources. It has been known since
the days of early Greece and Rome. The word
asbestos is of Greek derivation.

• Chrysotile is the asbestos most often found in

textiles. The fibers have good strength,
flexibility, toughness, low conductivity and
adequate length of spinning into yams. They
also have a silky texture. The most important
property of asbestos is that it is thermally
stable, i.e., it is not destroyed by the fire.
Asbestos is used for making fire smothering
blankets, protective mitts for cooking and
protective pads for tables and stoves. It is also
used in the industry to make cards and sheets.
It can also be blended with rayon and cotton.

• The use of asbestos is critical to health as it

settles in the lungs and causes asbestosis.
 • Glass is made up of silica sand and lime
stone. Glass fiber is strong with a 100%
MAN – elastic recovery. The fibers are smooth, even
and transparent with a circular cross–section.
MADE Glass, like asbestos is thermally and
MINERAL chemically stable.

FIBERS: • Used for making furniture, car bodies and

bullet proof jackets
GLASS FIBER
 • Manufacture of Man-Made Fiber
• Synthetic Fibers
Man Made •
•
Types of Nylon
Polyester
Fibers • Acrylic
• Olefin
• Rubber
• Spandex
 MANUFACTURE OF MAN MADE
FIBER
Man made fiber is produced by passing a chemical substance called polymer or dope through a
spinerette. This device consists of a series of tiny holes. As the fiber substance emerges from the
spinerette or is extruded from the spinerette it hardens and coagulates into a fine filament.

• The Shape of the Filament Depends upon:

• (a) The size of the holes in the spinerette. Tiny holes give fine filaments and bigger holes give
thicker filaments.

• (b) The shape of the holes gives different cross–sections to the filament.

• (c) The amount of pressure applied during extrusion of the polymer from the spinerette,
pressure can be varied at regular intervals to give a textured filament.

• (d) Colour pigments can be added to the polymer solution to colour filaments.

• (e) Other additives like delustering pigments (titanium dioxide) can be added to the polymer
before extrusion.
 Extrusion

• Extrusion is similar to injection moulding except that the plastic is

forced through a die rather than into a mould. However, the
disadvantage of extrusion is that the objects

• made must have the same cross-sectional shape. Plastic tubing and
hose is produced in this manner.
 Spinning

• The process of producing fibers is called spinning. There are three main
types of spinning: melt, dry, and wet. Melt spinning is used for polymers
that can be melted easily. Dry spinning involves dissolving the polymer into
a solution that can be evaporated. Wet spinning is used when the solvent
cannot be evaporated and must be removed by chemical means.

• All types of spinning use the same principle, so it is convenient to just

describe just one. In melt spinning, a mass of polymer is heated until it will
flow. The molten polymer is pumped to the face of a metal disk containing
many small holes, called the spinneret. Tiny streams of polymer that emerge
from these holes (called filaments) are wound together as they solidify,
forming a long fiber. Speeds of up to 2500 feet/minute can be employed in
spinning
The manufacturing process is the same for all man made fibers. The spinerette
extrudes the filaments into different environments, i.e., chambers that either
have some liquid and hot air to coagulate the filament. The spinning of
manufactured fibers thus falls into four categories.

Polymer that is to be converted into fibre must first be converted to a liquid or

semiliquid state, either by being dissolved in a solvent or by being heated until
molten. This process frees the long molecules from close association with one
another, allowing them to move independently. The resulting liquid is extruded
through small holes in a device known as a spinerette…
• (a) Wet Spinning:
The filaments are extruded into a liquid that causes
coagulation of the filament.

• Dry Spinning:
The filaments are extruded into a chamber of warm air,
which causes the solvent to evaporate thus hardening the
filament.

• (c) Melt Spinning:

The polymer is forced through the spinerette into an
environment that causes the solution to harden into a
filament from, without any chemical change in the fiber
form.

• (d) Emulsion Spinning:

The polymer is dispersed into the solution. Dispersion
solution dries up as the fiber is being spun.
 Stages in the melt spinning of polymeric fibres

Various cross sections of Different shapes of holes present on the

manmade filaments spinnerets give different cross sections
of filaments
 Synthetic and
Cellulosic Fiber
Formation Technology

• Most synthetic and

cellulosic manufactured
fibers are created by
• ―extrusion‖ — forcing a
thick, viscous liquid (about
the consistency of cold
honey) through the tiny
holes of a device called a
spinneret to form
continuous filaments of
semi-solid polymer.
•In their initial state, the fiber- forming polymers are solids and therefore must be
first converted into a fluid state for extrusion. This is usually achieved by melting, if
the polymers are thermoplastic synthetics (i.e., they soften and melt when
heated), or by dissolving them in a suitable solvent if they are non-thermoplastic
cellulosic.

•If they cannot be dissolved or melted directly, they must be chemically

•treated to form soluble or thermoplastic derivatives. Recent technologies have
been developed for some specialty fibers made of polymers that do not melt,
dissolve, or

•form appropriate derivatives. For these materials, the small fluid molecules are
mixed and reacted to form the otherwise intractable polymers during the extrusion
process
 The Spinneret

• The spinnerets used in the

production of most manufactured
fibers are similar, in principle, to a
bathroom shower head. A spinneret
may have from one to several
hundred holes. The tiny openings
are very sensitive to impurities and
corrosion. The liquid feeding them
must be carefully filtered (not an
easy task with very viscous
materials) and, in some cases, the
spinneret must be made from very
expensive, corrosion-resistant
metals. Maintenance is also
• critical, and spinnerets must be
removed and cleaned on a regular
basis to prevent clogging.
•As the filaments emerge from the holes in the spinneret, the liquid
polymer is converted first to a rubbery state and then solidified. This
process of extrusion and solidification of endless filaments is called
spinning, not to be confused with the textile operation of the same
name, where short pieces of staple fiber are twisted into yarn. There
are four methods of spinning filaments of manufactured fibers: wet,
dry, melt, and gel spinning.
 Wet Spinning

• Wet spinning is the oldest process. It is used for fiber-forming

substances that have been dissolved in a solvent. The spinnerets
are submerged in a chemical bath and as the filaments emerge
they precipitate from solution and solidify.

• Because the solution is extruded directly into the precipitating

liquid, this process for making fibers is called wet spinning. Acrylic,
rayon, aramid, mod acrylic and spandex can be produced by this
process.
 Dry Spinning

• Dry spinning is also used for fiber-forming

substances in solution. However, instead of
precipitating the polymer by dilution or
chemical reaction, solidification is
achieved by evaporating the solvent in a
stream of air or inert gas.

• The filaments do not come in contact with

a precipitating liquid, eliminating the need
for drying and easing solvent recovery.
This process may be used for the
production of acetate, triacetate, acrylic,
mod acrylic, PBI, spandex, and vinyon.
Melt Spinning

•In melt spinning, the fiber-forming substance is melted

for extrusion through the spinneret and then directly
solidified by cooling. Nylon, olefin, polyester, saran and
Sulphur are produced in this manner.

•Melt spun fibers can be extruded from the spinneret in

different cross- sectional shapes (round, trilobal,
pentagonal, octagonal, and others) . Trilobal-shaped
fibers reflect more light and give an attractive sparkle to
textiles.
Pentagonal-shaped and hollow fibers, when used in
carpet, show less soil and dirt. Octagonal-shaped fibers
offer glitter-free effects. Hollow fibers trap air, creating
insulation and provide loft characteristics equal to, or
better than, down.
Gel Spinning

• Gel spinning is a special process used to obtain high strength or other special fiber
properties. The polymer is not in a true liquid state during extrusion. Not
completely separated, as they would be in a true solution, the polymer chains are
bound together at various points in liquid crystal form. This produces strong inter-
chain forces in the resulting filaments that can significantly increase the tensile
strength of the fibers.
• In addition, the liquid crystals are aligned along the fiber axis by the shear forces
during extrusion. The filaments emerge with an unusually high degree of
orientation relative to each other, further enhancing strength. The process can also
be described as dry-wet spinning, since the filaments first pass through air and then
are cooled further in a liquid bath. Some high-strength polyethylene and aramid
fibers are produced by gel spinning.
 Stretching and Orientation

• While extruded fibers are solidifying, or in some cases even after they have
hardened, the filaments may be drawn to impart strength. Drawing pulls the
molecular chains together and orients them along the fiber axis, creating a
considerably stronger yarn.
 SYNTHETIC FIBERS

Nylon
• Nylon was the first introduced to the world in 1938
by DuPont.

• Nylon 6, 6 is a polymer made from hexam ethylene

and acidic acid. The two chemicals are combined to
form the nylon salt, which is melted and passed
through the spinerette to extrude the nylon filament.

• Well known trademarks of nylon 6,6 are Dupont

nylon, Antron, Ultron and Well on.

• Nylon 6 manufactured by the polymerization of

caprolactum, melted and extruded.

• Trademarks are Caprolan, Euka, Shareen, Zefran

nylon and Zefton
Nylon Chip Nylon Fiber
 Properties

• 1. Shape --Smooth, shiny with a slight speckle. The diameter is uniform and
can be controlled.
• 2. Lustre --- --It is controllable from bright to dull.
• 3. Strength --- Good.
• 4. Resiliency ---- Very Good.
• 5. Moisture Absorption ---- Poor.
• 6. Dimensional Stability --- Good.
• 7. Resistance to acids ----Poor.
• 8. Resistance to Alkalis ----- Good Resistance.
• 9. Resistance to Sunlight ----- Nylon is destroyed unless a finish is applied.
• 10. Micro organisms ---- Not attacked by mildew and rot.
• 11. Resistance to Insects ----- May be damaged by ants and cockroaches.
• 12. Heat ----- Softens and melt.
• 13. Flame -- Shrinks away from the flame and is considered self
extinguishing.
Photomicrograph of nylon6, 6 Fiber: nylon Fiber,
longitudinal view. Cross section
Photomicrograph of trilobal nylon, cross
section of Antron nylon
 • 1. Qiana Nylon
• 2. Nylon 11
• 3. Nylon 6,10

Nylon is a popular fabric for apparel and

home furnishings. Due to its easy care
procedures good dimensional stability and
OF
TYPES resiliency it has taken over the market in no
time. Lingerie socks, swimwear, leotards,

NYLON wind breakers and parkas are commonly

made with nylon.

Tufted carpets, draperies and upholstery of

nylon perform well.

Car interiors, parachutes, ropes, sporting

goods, golf bags, umbrellas, toothbrushes
are some of the industrial uses.
 • Nylon is a poly amide fiber; aramid is an aromatic poly
amide fiber. It is a nylon variant with exceptional strength
and fire resistance. Aramid fibers are a class of heat-
resistant and strong synthetic fibers. They are used in
aerospace and military applications, for ballistic rated
body Armor fabric, and as an asbestos substitute. The
name is a shortened form of "aromatic polyamide". They
are fibers in which the chain molecules are highly oriented
along the fiber axis, so the strength of the chemical bond
can be exploited. A manufactured fiber in which the fiber-
forming substance is a

Aramid • long-chain synthetic polyamide in which at least 85% of

the amide linkages, (-CO- NH-) are attached directly to
two aromatic rings

• Aramid fibers have high tenacity and high resistance to

stretch and chemicals. Aramids are prone to static build up
unless finished. Tradenames are Nomex, Kelvar, Conex,
and Kermal Kevlar around is five time stronger than steel.
It is used for re– inforcement of radial tyres and also for
making bullet proof jackets. Nomex aramid is used for
making a protective clothing such as fire fighters‘ apparel.
 POLYESTER

• The first polyester fiber, terylene was produced in England. It was first
introduced in the United States by the DuPont under the name Dairon.

• Production
• Polyester is produced by reacting dicarboxylic acid with dihydric alcohol. It is
melted and passed through the spinerette and retains the shape of the hole.
Modifications in cross–sectional shape are inexpensive and easy to produce.
 Properties

• 1. Shape - Controlled by Manufacturer.

• 2. Lustre - Controlled by Manufacturer from semi bright to dull.
• 3. Resiliency - Excellent
• 4. Dimensional stability - Excellent
• 5. Moisture absorption - Very Low
• 6. Resistance to Acids - Strong Acids destroy the fiber
• 7. Alkalis- Good
• 8. Sunlight - Behind glass resistance is excellent; but not in
direct sunlight.
• 9. Micro Organisms - Excellent
• 10. Insects - Excellent
• 11. Reaction to heat - Will melt at 238O C to 290O C.
• 12. Flame - Will burn slowly and drop off preventing further
Photomicrograph of regular polyester Photomicrograph of regular polyester
fiber. Longitudinal view. fiber. Cross-section view
 Modified Polyester Fibers

• 1. Benzoate polyesters
• 2. Flame retardant polyester
• 3. POY Polyester
Polyester is widely used as a blend or otherwise in woven fabrics used for apparel
and furnishings. Polyester knits well and is used for making knitted shirts and
blouses. Polyester is used as a fiberfit (polyfill) in pillows, quilts and padding. It is
light weight and washable as compared to a cotton filling and had thus gained a lot
of popularity. Non–woven polyester is used for making bandages and pads in the
medical field.

Polyester is easy to care as it can be washed in the washing machines using warm
water. Hot water (120O–140O F) causes wrinkling on the fabric. Polyester is
oleophilic, i.e., tends to attract oily soils making the fabric look dingy over a period
of use. Soil release finishes can solve this problem.
 ACRYLIC

• Acrylonitrile, the substance from which Acrylic is made, was first found in
Germany in 1893. The marketing of acrylic fibers frequently takes advantage
because of its wool like characteristics. It has been given the trademark Orlon
by DuPont.

• Production:
Acrylic fibers are formed by the addition polymerization of acrylonitrile (vinyl
cyanide). Solvents dissolve the polymer to permit extrusion through the spinerette.
 Properties
• 1. Shape -- Controlled by the manufacturer. The cross–section could be
triangular, circular, etc.
• 2. Lustre - From bright to dull depending on the end use.
• 3. Resiliency - Good.
• 4. Moisture - Poor. Absorption
• 5. Dimensional - Good with correct procedures Stability
• 6. Resistance to acids - Good resistance to weak acids.
• 7. Resistance to Alkalis - Good resistance to weak alkalis;
destroyed by strong alkalis.

• 8. Sunlight -Excellent.
• 9. Micro organisms- Excellent.
• 10. Insects - Excellent.
• 11. Reaction to Heat - Maintain temperature below 160O C.
• 12. Flame - Burns with a sputtering flame melts and drops and takes the
fire along with it.
•Acrylic fibers are soft, warm light weight and resilient. They make easy care fabric and are
often referred to as ―warmth without weight‖. They are superior to wool in care and
storage procedure. Acrylic is used for making take furs, socks, coats, jackets and soft stuffed
animals. Very often it is blended with wool to make blankets. Pure acrylic blankets and
carpets are lightweight warm and washable and cost less than wool.

•In the industry acrylic is used to make tents, awnings, sand bags and office dividers. It is also
widely used for upholstery, draperies in the furnishing industry.

•In India Pashupati Acrylon Ltd. near Delhi manufactures acrylic.

•Acrylic has good wash and wear characteristics. It can be laundered in the washing machine
or dry cleaned. Alkali and chrome can damage the fibers.
 MODACRYLIC
Mod acrylic fibers are modified acrylics first produced in the United States in
1949.

Mod acrylics were the first inherently flame retardant synthetic fibers; they do
not support combustion and are very difficult to ignite. They are self
extinguishing and do not drip. x

• Production:
Mod acrylic fibers are produced by polymerization of acronytriles and adding
other polymers to make a co–polymer. The co–polymer is dissolved in acetone
and pumped through the spinneret.
 Properties & Uses of Mod acrylic

• Properties:
Mod acrylic are poor conductors of heat. Fabrics are soft, warm and have a
tendency to pill. They are resistant to acids, alkalis, sunlight, mildew, rot and
moths. Mod acrylics have a very good flame resistance.

• Uses:
Major uses of mod acrylic include flame retardant fabrics for children sleepwear,
elderly sleepwear, upholstery, drapery, protective clothing for fire fighters.
 OLEFIN

Olefin fibers are chemically polypropylene and were first produced in Italy in
1957.

Production:
There are two basic types of olefin:–

(a) Polyethylene – polymerized from ethylene.

(b) Polypropylene – polymerised from propylene.

The raw material is extended through the spinrette After the filaments are
cooled, they can be stretched six times the spun length
 Shape - Can be controlled.

Lustre - Control from bright to dull.

Resiliency - Good

Moisture Absorption - Poor

Dimensional Stability - Ismaintained, if below120O

Resistance to acids – Excellent

Resistance to Alkalis –Excellent

Properties
Resistance to Sunlight -Degrade in sunlight

Micro-organisms - Good .

Resistance to Insects - Good.

Reaction to Heat - Melts at low temperature and shrinks

Resistance to Flame -Burns readily and emits heavy

sooty waxy -
 USES

• Olefin fibers are used for sports apparel like swimmer and ski jackets.

• In the furnishing industry it is used for non–woven, needle punched carpets, It

has replaced jute for making a backing for carpets, because of low cost and
excellent durability. to make road bed support fabrics like petro mat and
petrotak, that provide a water and particle barrier between road surface and
underlying soil foundation.

• It is also used for making car interiors, sand bags, laundry bags, and ropes.
Some trade names are Tyvek, Spectra 900, Spectra 1000 and polyloom
 Elastomeric Fibers

Elastomers are elastic, rubber like substances.

All elastomers are characterized by extremely high elongation and out standing
elastic recovery.
 Rubber

• Rubber is a manufactured fiber in which the fiber forming substance is either

natural or synthetic rubber.

• Natural rubber is a thick gummy liquid obtained from the trees of the Heave
species. Good Year‘s Process – Now known as vulcanizing, set the scene for the
development of rubber in many forms.

• Synthetic rubber neoprene first developed in 1930s. It gained importance only

in the world war Ii when the supply of natural rubber was cut off.
 Properties
Properties that make rubber desirable are :–
High degree of elasticity.
Flexibility.
Strength
Impermeable to water and air.
Resistance to cutting and tearing.
Resistance to many chemicals.

Properties of rubber that can cause problems.

a) Deterioration by sunlight and smog.
b) Loss of strength and elasticity through aging.
c) Damage by cleaning solvents.
d) Sensitive to above 93O C that cause deterioration in flexibility.
 Use

• Rubber products tyres, car interiors, floorings and tiles. Rubber yarns are used

• for surgical fabrics, socks, shoes and elastic yarns for decorative stitching.

• Rubber products can be laundered in warm water using synthetic detergents.

• Trade names for rubber are : Contro, Globe, Lastron, Lostex and Laton.
 SPANDEX

In 1958 DuPont introduced Spandex, the first manufactured elastic fiber called
lycra. Spandex is produced by DuPont under the trade name lycra and by globe
manufacturing Company under the trade names glospan and clear span. Spandex is
also known as elastin.

Production
Spandex fibers are made by reacting polyether molecules with di–isocyanate and
polymerizing. The polymer solution may contain delusturing agents, dye receptors,
whiteners and lubricants. The polymer solution is then extended out through the
spinerette.
 Properties & Uses of Spandex

Properties:

Spandex is seldom used alone in the fabrics. It is blended with nylon, cotton or other fibers to give
them a stretch.

It is resistant to dilute acids, alkalis, bleaches and dry cleaning solvents. It has a good resiliency
and excellent elastic recovery. Spandex has poor moisture absorption.

Uses:

• It has superior aging resistance than rubber and resists soiling.

• Spandex is used to support shape or mould the body or to keep the textiles from stretching out
of shape. It is used primarily in knitted foundation garments, action wear, sports wear, lingere
and legging. It is also used in woven fabrics to give them stretch.