Millenium Fibres

Paper by

Mr. Lav Ahuja

Final Year B.Text ( 2001-02 Batch ),

DKTE, Textile & Engineering Institute, Ichalkaranji, India.

Fibre Consumption Trend Towards New Millenium

Worldwide Fibre Production Share By Fibre Type

1980

2000

Ø Man Made Fibre Production is increasing tremendously

Ø Polyester production share has moved from 35% in 1980 to 56% in 2000, a 21% absolute share gain.

Ø Olefin share has grown from 7% in 1980 to 18% in 2000.

Ø Cellulosic fibre production share has been tremendously reduced from 22% in 1980 to just 6% in year 2000.

Ø This clearly indicates that Polyster and Olefin Fibres play major role in new millennium.

Ø But the role of each fibre and its importance with respect to application can’t be underestimated.

Major Fibres Available,Their Characteristics And Uses

Major Generic Fibers	Characteristics	Major Domestic and Industrial Uses
ACETATE	Luxurious feel and appearance Wide range of colors and luster Excellent drapability and softness Relatively fast-drying Shrink-, moth-, and mildew-resistant	Apparel: Blouses, dresses, and foundation garments. lingerie, linings, shirts, slacks, sportswear. Fabrics: Brocade, crepe, double knits, faille, knitted jerseys, lace, satin, taffeta, tricot. Home Furnishings: Draperies, upholstery. Other: Cigarette filters, fiberfill for pillows, quilted products
ACRYLIC	Soft and warm Wool-like Retains shape Resilient Quick-drying Resistant to moths, sunlight, oil and chemicals	Apparel: Dresses, infant wear, knitted garments, ski wear, socks, sportswear, sweaters. Fabrics: Fleece and pile fabrics, face fabrics in bonded fabrics, simulated furs., jerseys. Home Furnishings: Blankets. carpets, draperies, upholstery. Other: Auto tops, awnings, hand-knitting and craft yarns, industrial and geotextile fabrics.
ARAMID	Does not melt Highly flame-resistant High strength High resistance to stretch Maintains its shape and form at high temperatures	Hot-gas filtration fabrics, protective clothing, military helmets, protective vests, structural composites for aircraft and boats, sailcloth, tires, ropes and cables, mechanical rubber goods, marine and sporting goods.
BICOMPONENT	Thermal bonding Self bulking Very fine fibers Unique cross sections The functionality of special polymers or additives at reduced cost	Uniform distribution of adhesive, Fiber remains a part of structure and adds integrity, Customized sheath materials to bond various materials, Wide range of bonding temperatures, Cleaner, environmentally friendly (no effluent), Recyclable, Lamination / molding / densification of composites.
LYOCELL	Soft, strong, absorbent Good dyeability Fibrillates during wet processing to produce special textures	Dresses, slacks and coats.
NYLON	Exceptionally strong Supple Abrasion-resistant Lustrous Easy to wash Resists damage from oil and many chemicals Resilient Low in moisture absorbency	Apparel: Blouses, dresses, foundation garments, hosiery, lingerie and underwear, raincoats, ski and snow apparel, suits, windbreakers. Home Furnishings: Bedspreads, carpets, draperies, curtains, upholstery. Other: Air hoses, conveyor and seat belts, parachutes, racket strings, ropes and nets, sleeping bags, tarpaulins, tents, thread, tire cord, geotextiles.
OLEFIN	Unique wicking properties that make it very comfortable Abrasion-resistant Quick-drying Resistant to deterioration from chemicals, mildew, perspiration, rot, and weather Sensitive to heat Soil resistant Strong; very lightweight Excellent colorfastness	Apparel: Pantyhose, underwear, knitted sports shirts, men's half hose, men's knitted sportswear, sweaters. Home Furnishings: Carpet and carpet backing, slipcovers, upholstery. Other: Dye nets, filter fabrics, laundry and sandbags, geotextiles, automotive interiors, cordage, doll hair, industrial sewing thread.
POLYESTER	Strong Resistant to stretching and shrinking Resistant to most chemicals Quick-drying Crisp and resilient when wet or dry Wrinkle- and abrasion-resistant Retains heat-set pleats and creases Easy to wash	Apparel: Blouses, shirts, career apparel, children's wear, dresses, half hose, insulated garments, ties, lingerie and underwear, permanent press garments, slacks, suits. Home Furnishings: Carpets, curtains, draperies, sheets and pillow cases. Other: Fiberfill for various products, fire hose, power belting, ropes and nets, tire cord, sail, V-belts.
RAYON	Highly absorbent Soft and comfortable Easy to dye Versatile Good drapability	Apparel: Blouses, coats, dresses, jackets, lingerie, linings, millinery. rainwear, slacks, sports shirts, sportswear, suits, ties, work clothes. Home Furnishings: Bedspreads, blankets, carpets, curtains, draperies, sheets, slipcovers, tablecloths, upholstery. Other: Industrial products, medical,: surgical products, non-woven products, tire cord.
SPANDEX	Can be stretched 500 percent without breaking Can be stretched repeatedly and recover original length Light-weight Stronger and more durable than rubber Resistant to body oils	Articles (where stretch is desired): Athletic apparel, bathing suits, delicate laces, foundation garments, golf jackets, ski pants, slacks, support and surgical hose.

Major Fibre Producing Companies

Fibre Type	Trade Names	Manufacturer
ACETATE	4 Different Trade Names	Celanese Acetate Eastman Chemical Company
ACRYLIC	16 Trade Names	Solutia Inc. Sterling Fibers, Inc
ARAMID	Kevlar Nomex	DuPont Company DuPont Company
BICOMPONENT	AXXEL Resistat	Fiber Innovation Technology, Inc. BASF Corporation
FLUORO	Teflon	DuPont Company
LYOCELL	Fibro Galaxy Lyocell by Lenzing	Acordis Cellulosic Fibers, Inc. Acordis Cellulosic Fibers, Inc. Lenzing Fibers Corporation
MELAMINE	Basofil	BASF Corporation
MODACRYLIC	SEF Plus	Solutia Inc.
MODAL	Micro-ProModal MicroModal Modal by Lenzing Modal Sun ProModal	Lenzing Fibers Corporation Lenzing Fibers Corporation Lenzing Fibers Corporation Lenzing Fibers Corporation Lenzing Fibers Corporation
NYLON 6	36 Different Trade Names	Honeywell International BASF Corporation
NYLON 6.6	42 Different Trade Names	DuPont Company Solutia Inc. Acordis Industrial Fibers Inc. Nylstar,.Inc.

OLEFIN	Alpha BCF Essera Impressa Innova Marqesa Lana Permafresh Spectra 1000 Spectra 900 Spectra Fusion Spectra Guard Spectra Shield Spectra Shield Plus SpectraFlex Telar Trace Trace FR	American Fibers and Yarns Company American Fibers and Yarns Company American Fibers and Yarns Company American Fibers and Yarns Company American Fibers and Yarns Company Drake Extrusion Honeywell International Honeywell International Honeywell International Honeywell International Honeywell International Honeywell International Honeywell International Filament Fiber Technology, Inc American Fibers and Yarns Company American Fibers and Yarns Company
PBI	PBI Logo	Celanese Acetate A.G.
PELCO	Securus	Honeywell International
PEN	Pentex	Honeywell International
POLYESTER	More than 60 Trade Name	Reliance Industries Ltd. Indo Rama. Honeywell International KoSa Martin Color-Fi, Inc. DuPont Company Wellman, Inc. Acordis Industrial Fibers, Inc. Honeywell International
RAYON	Fibro Galaxy Viscose by Lenzing Viscose FR by Lenzing	Acordis Cellulosic Fibers, Inc. Acordis Cellulosic Fibers, Inc. Lenzing Fibers Corporation Lenzing Fibers Corporation

Fiber Forms And Product Forms

1. Fibers are available in several different forms. The most common forms used are:

Ø Staple Fiber – filaments cut into specific lengths – usually spun into yarn

Ø Chopped Fiber –coarser,cut to specific, often short, lengths to add to mixture

Ø Monofilament – a single (large) continuous filament yarn – like fishing line

Ø Multifilament – extruded continuously with many filaments in the bundle.

2.These basic forms of fiber are then further processed into one of four major converted forms.These converted forms can be categorized into four groups:

Ø Spun yarn

Ø Knitted fabric

Ø Woven fabric

Ø Nonwoven fabric

2. Most are familiar with yarn, woven and knitted fabrics. Nonwoven fabrics may be another story. The most common types of nonwoven fabrics are – based on bonding and manufacturingprocesses - are:

Ø Needlefelts – the fibers are mechanically entangled with barbed needles

Ø Dry-laid – chemical or thermal bond – many different forms, including

Ø Direct formed - spunbond and melt-blown (may be further bonded or combined)

Ø Stitch Bond – sewn bond

Ø Wet-laid – paper making process

Ø Hydro-entangled (spunlace) – water jet entangled – mechanical bond

Many of the fibers are used in very similar end uses, but based on differences of specific properties, each fiber tends to find its own niche where it has an advantage over the others.

Newly Invented Fibres – Properties and Applications

A. Meta-aramid: Nomex® (DuPont), TeijinConex®, TeijinConex HT® (Teijin)

Ø Perhaps the best known and most widely used of the aramid fibers (Nomex is familiar to many), meta-aramids are best known for their combination of heat resistance and strength.

Ø Meta-aramid fibers do not ignite, melt or drip; a major reason for their success in the FR apparel market.

Ø In comparison to commodity fibers, meta-aramids offer better long-term retention of mechanical properties at elevated temperatures. Meta-aramids have a relatively soft hand and tend to process very similarly to conventional fibers, giving them a wide range of converted products. Meta-aramids are available in a variety of forms, anti-stat, conductive, in blends (with other high performance fibers), etc.

Ø TeijinConex HT high tenacity type meta-aramid has significantly higher tensile strength of other meta-aramids. This high strength allows it to bridge the gap between meta-aramid and para-aramid fiber when strength is the primary concern.

M-aramid Properties	Value
Tenacity g/de	3.8-7.2
Elongation (%)	25-40
Limiting Oxygen Index	30
Chemical resistance	Mild-Good
Operating temperature	4000 F

Typical Applications for Meta-Aramid Fabrics

Form	Application
Needlefelt	· Automotive · Business machine parts · Cushion material · Hot gas filtration · Safety & Protective clothing · Thermal insulation · Thermal spacers ·
Woven fabric	· Hot gas filtration · Loudspeaker components · Reinforcement: composites and rubber · Safety & Protective clothing · Thermal insulation
Wet-laid nonwoven	· Business machine parts · Battery separators · Heat shields
Dry laid nonwoven	· Business machine parts · Electrical insulation · Heat shields · Hot gas filtration · Laminate support base · Thermal spacers
Spunlace nonwoven	· High temperature filtration · Safety & Protective clothing · Laminate support base

B. Para-aramid: Kevlar® (DuPont), Twaron® (Acordis), Technora® (Teijin)

Due to their highly oriented rigid molecular structure, para-aramid fibers have high

Ø tenacity, high tensile modulus and high heat resistance.

Ø Para-aramid fibers have similar operating temperatures to meta-aramid fibers, but have 3 to 7 times higher strength andmodulus, making them ideal for reinforcement and protective type applications.

There are two types of para-oriented aramid fibers:

Ø Homo-polymer - Kevlar and Twaron

Ø Co-polymer – Technora

Ø Although para-aramids are high in strength, there is some problem with chemical resistance.

Ø Homopolymer para-aramids have relatively weak resistance to strong acids andbases. Kevlar and Twaron, for instance, cannot be bleached with chlorine and are often notapproved for food handling in protective gloves.

Ø The fine surface structure of Technora copolymer allows it to have much higher chemical resistance. Kevlar has new forms with increased strength and improved properties.

Ø Co-polymer para-aramids have advantages with increased abrasion resistance and steamresistance – useful properties in many protective applications.

Typical properties of para-aramids are as follows:

Properties	Value
Tenacity g/de	22 - 26
Modulus g/de	460 -1100
Elongation (%)	2.4 – 4.4
Limiting Oxygen Index	25 - 28
Chemical resistance	Mild - Good
Operating temperature	375

B. Para-aramid: Kevlar® (DuPont), Twaron® (Acordis), Technora® (Teijin)

Continued…

Ø Para-aramids are often blended with other fibers to impart some of their high strength properties to the blend or mix.

Ø A 60/40 blend of Kevlar and PBI, is the most widely used material for firemen’s premium turn out coats.

Ø The Kevlar helps overcome some of the “textile”deficiencies (processing, strength) in the PBI; the PBI’s softness, moisture regain, and high temperature properties improves the performance characteristics of the Kevlar.

Applications :

Form	Application
Needlefelt	· Cushion material · Safety and protective clothing · Thermal insulation · Thermal barriers
Woven fabric	· Reinforcement: composites and rubber · Sporting goods · Thermal insulation · Mechanical rubber goods · Safety and protective clothing · Ballistic application
Wet-laid nonwoven	· Friction materials · Heat shields
Yarn	· Reinforcement: composites and rubber · Sewing thread · Ropes and cables · Safety and protective clothing (sewing thread)

C. Fluorocarbon fibers (PTFE) : Teflon® (duPont), Toyoflon® (Toray)

Ø PTFE (polytetrafluoroethylene) fibers offer a unique blend of chemical and temperature resistance, coupled with a low friction coefficient.

Ø PTFE is virtually chemically inert, and is able to withstand exposure to extremely harsh environments.

Ø The coefficient of friction for PTFE, the lowest of all fibers, makes the fiber suitable for a wide range of applications such as bearing replacement material and release material when stickiness is a concern.

Ø The fiber’s low friction coefficient, as well as their low tensile strength, makes PTFE fibers difficult to process, and difficult to blend with other fibers. PTFE sewing thread is ideal for a number of PC and harsh applications. The material is also made into breathable, porous membranes laminated to fabrics for protective uses.

The following properties area typical of PTFE materials

PTFE Properties	Value
Tenacity g/de	2
Elongation (%)	25
Limiting Oxygen Index	95
Chemical resistance	Excellent
Friction Coefficient	0.2
Operating temperature	500

Applications

Form	Application
Needlefelt	Automotive Bearing replacement Hot gas filtration Release fabrics
Woven fabric	Conveyor belts Mechanical rubber goods Gasket tape
Wet-laid nonwoven	Battery separators Heat shields Liquid filtration
Membrances	Filtration Safety and Protective (vapor barriers, breathable membranes)
Yarn	Mechanical rubber good Sewing thread
Monofilament	Release fabrics Filtration fabrics

D. PBI: PBI (Celanese)

Ø Polybenzimidazole is an organic fiber with excellent thermal resistant properties and a good hand.

Ø PBI does not burn in air and does not melt or drip. The high LOI coupled with its good chemical resistance and good moisture regain make PBI an excellent fiber for fire blocking end uses such as safety and protective clothing and flame retardant fabrics.

Ø Its physical properties are relatively low, but PBI is processed onmost types of textile equipment.

Ø It blends well with other materials such as carbon and aramid fibers and is most often done for performance reasons as well as cost. PBI has had significant success in the fireman's apparel market where, blended in a 60/40 para-aramid/PBI mixture, it has become the standard “premium” material.

Ø PBI’s characteristic gold color blends well with other materials for a pleasing appearance. Its main drawback is its very high price – over $70 per pound.

Properties

PBI Properties	Value
Tenacity g/de	2.7
Modulus g/de	32
Elongation (%)	29
Limiting Oxygen Index	41
Chemical resistance	Good - Excellent
Operating temperature (^OF)	482

Typical Applications

Form	Application
Needle Felt	· Thermal insulation · Safety and protective · Fire blocking
Woven Fabric	· Thermal insulation · Safety and protective clothing

E. Carbon Fiber: PAN (polyacrylonitrile) and Pitch based

Ø There are different categories of carbon fibers based on modulus, tensile strength, and final heat treatment temperature.

Ø In the carbonization process, temperature exposures range from 10000 C to 20000 C, each different level of exposure creating a different property for the fiber.

Ø For example, high-modulus type is processed at 20000 C, 15000 C for high strength type, and 10000 C for low modulus and low strength type.

Ø The main carbon fibers are made from polyacrylonitrile (PAN) based and pitch based, and are well known for their composite ,reinforcement and heat resistant end uses.

Properties

Properties	PAN	PITCH
Tenacity g/de	18 – 70	14 - 30
Modulus g/de	1640 – 3850	1000 – 5850
Elongation (%)	0.4 – 2.4	0.2 – 1.3
Continues operating temperature	570-1000	570-1000

Allpications

Form	Application
Woven Fabric	· Aircraft and aerospace · Automotive · Sports & recreational equipment · Marine · General engineering
Yarn / Fibre	· Reinforcement composites and rubber · Filtration

F. Glass

Ø Glass is an inorganic fiber, which is neither oriented nor crystalline.

Ø Glass fibers were one of the first “man-made” fibers, commercialized in the late 30’s.

Ø Widely used as insulation (glass batts in home insulation and industrial insulation in mats and fabric form).

Ø It is widely used in reinforcing thermoplastic composites in products from circuit boards to boat hulls. High temperature filtration is another high volume use.

Ø The ingredients normally used in making glass fibers are: silicon dioxide, calcium oxide, aluminum oxide, baron oxide, plus a few other metal oxides.

Glass types:

A - Alkali-containing glass composition.

AR - Alkali-resistant for reinforcing cement.

C - Chemically-resistant glass composition.

E - Standard uses, this composition has high electrical resistance.

HS - Magnesium-alumina-silica glass. High strength.

S - Composition similar to HS glass.

The following chart is representative of the properties of various glass fibers.

Properties	E-glass	AR-Glass	S-glass
Tenacity g/de	35	45	35
Modulus g/de	524	1250	620
Elongation (%)	4.8	2	5.4
Refractive Index	1.547	1.561	-
Density (g/cm^3)	2.57	2.68	2.46
Coefficient of thermal expansion (10^7 0C)	50 – 52	75	23 – 27
Dielectric(10^10Hz) Constant	6.1 – 6.3	--	--

Glass Fibre Applications

Form	Application
Needle Felt	· Aircraft and aerospace · Cushion material · Filtration · Thermal insulation and · Acoustic insulation
Woven Fabric	· Automotive · Filtration · Reinforcement - plastic/rubber/cement · Thermal insulation · Printed circuit boards - electrical

G. High Density Polyethylene - HDPE: Spectra® (Honeywell), Dyneema® (Dyneema)

Ø HDPE fibers offer strength similar to that of para-aramids.

Ø Developed in Japan by Dyneema, and known throughout the world as Dyneema, except in the US where the process is licensed to AlliedSignal and is known as Spectra.

Ø Light in weight, the fiber has a specific gravity of less than 1, tough yet lighweight products can be made, including rope and cordage that floats as well as soft and semi-rigid body armor and in cut resistant materials such as gloves that are lighter than competitors, reducing fatigue in use.

Ø In addition to high tenacity, HDPE fibers have very good abrasion resistance and excellent chemical and electrical resistance.

Ø HDPE fibers are inherently “slick” and difficult to adhere to, a drawback in some areas but not of concern in others.

Ø They can be bleached and sterilized and used for food handling gloves, among others.

Ø The HDPE fibers have low melting points, however, so their continuous operation temperature is a relatively low.

HDPE Properties	Value
Tenacity g/de	30
Modulus g/de	1400
Elongation (%)	3
Chemical resistance	Excellent
Operating temperature (^OF)	250

Applications

Form	Application
Yarns	· Marine ropes and cordage · Sail cloth
Woven Fabric	· Marine · Safety and protective products Reinforcement of composites (sport, pressure vessels, boat hulls, implants) Medical

Conclusion

q Innovation is the hallmark of the fibre industry.

q Fibres more numerous and diverse than any found in nature are now routinely created in the industry's laboratories.

q The revolutionary new fibers are modified to offer greater comfort, provide flame resistance, reduce clinging, release soil, achieve greater whiteness, special dullness or luster, easier dyeability, and better blending qualities with Endless Possibilities.

q These innovations in fibres made it possible that Textiles are now being used in Each and Every Industry.

q As they always have, fibers continue to mean, “life made better”.

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