Synthetic fibers are the result of extensive research by
scientistA scientist in a broad sense is one engaging in a systematic activity to acquire knowledge. In a more restricted sense, a scientist is an individual who uses the scientific method. The person may be an expert in one or more areas of science. This article focuses on the more restricted use of the word...
s to improve on naturally occurring
animalAnimal fibers are natural fibers that consist largely of particular proteins. Instances are silk, hair/fur and feathers. The animal fibers used most commonly both in the manufacturing world as well as by the hand spinners are wool from domestic sheep and silk. Also very popular are alpaca fiber...
and plant
fiberFiber is a class of materials that are continuous filaments or are in discrete elongated pieces, similar to lengths of thread.They are very important in the biology of both plants and animals, for holding tissues together....
s. In general, synthetic fibers are created by forcing, usually through
extrusionExtrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section...
, fiber forming materials through holes (called spinnerets) into the air, forming a thread. Before synthetic fibers were developed, artificially manufactured fibers were made from
celluloseCellulose is an organic compound with the formula , a polysaccharide consisting of a linear chain of several hundred to over ten thousand β linked D-glucose units....
, which comes from plants. These fibers are called
cellulose fiberCellulose fibers are fibres of cellulose from any source, either natural or manufactured.-Textile:In the textile industry regenerated cellulose is used as fibers such as rayon, . Cellulose fibers are manufactured from dissolving pulp...
s.
Synthetic Fibers are made from synthesized polymers or small molecules. The compounds that are used to make these fibers come from raw materials such as petroleum based chemicals or petrochemicals. These materials are polymerized into a long, linear chemical that bond two adjacent carbon atoms. Differing chemical compounds will be used to produce different types of fibers. Although there are several different synthetic fibers, they generally have the same common properties. Generally, they are known for being:
• Heat-sensitive
• Resistant to most chemicals
• Resistant to insects, fungi and rot
• Low moisture absorbency
• Oleophilic
• Electrostatic
• Flame resistant
• Density or specific gravity
• Pilling
There are several methods of manufacturing synthetic fibers but the most common is the Melt-Spinning Process. It involves heating the fiber until it begins to melt, then you must draw out the melt with tweezers as quickly as possible. The next step would be to draw the molecules by aligning them in a parallel arrangement. This brings the fibers closer together and allows them to crystallize and orient. Lastly, is Heat-Setting. This utilizes heat to permeate the shape and dimensions of the fabrics made from heat-sensitive fibers.
Synthetic fibers account for about half of all fiber usage, with applications in every field of fiber and textile technology. Although many classes of fiber based on synthetic polymers have been evaluated as potentially valuable commercial products, four of them -
nylonNylon is a generic designation for a family of synthetic polymers known generically as polyamides, first produced on February 28, 1935, by Wallace Carothers at DuPont's research facility at the DuPont Experimental Station...
,
polyesterPolyester is a category of polymers which contain the ester functional group in their main chain. Although there are many polyesters, the term "polyester" as a specific material most commonly refers to polyethylene terephthalate...
,
acrylicAcrylic fibers are synthetic fibers made from a polymer with an average molecular weight of ~100,000, about 1900 monomer units. To be called acrylic in the U.S, the polymer must contain at least 85% acrylonitrile monomer. Typical comonomers are vinyl acetate or methyl acrylate...
and
polyolefinA polyolefin is a polymer produced from a simple olefin as a monomer. For example, polyethylene is the polyolefin produced by polymerizing the olefin ethylene. An equivalent term is polyalkene; this is a more modern term, although polyolefin is still used in the petrochemical industry...
- dominate the market. These four account for approximately 98 per cent by volume of synthetic fiber production, with polyester alone accounting for around 60 per cent.
History
The first artificial fiber, known as artificial silk, became known as
viscoseViscose is a viscous organic liquid used to make rayon and cellophane. Viscose is becoming synonymous with rayon, a soft material commonly used in shirts, shorts, coats, jackets, and other outer wear.-Manufacture:...
around 1894, and finally
rayonRayon is a manufactured regenerated cellulose fiber. Because it is produced from naturally occurring polymers, it is neither a truly synthetic fiber nor a natural fiber; it is a semi-synthetic or artificial fiber. Rayon is known by the names viscose rayon and art silk in the textile industry...
in 1924. A similar product known as
cellulose acetateCellulose acetate , first prepared in 1865, is the acetate ester of cellulose. Cellulose acetate is used as a film base in photography, as a component in some adhesives, and as a frame material for eyeglasses; it is also used as a synthetic fiber and in the manufacture of cigarette filters and...
was discovered in 1865. Rayon and acetate are both artificial fibers, but not truly synthetic, being made from
woodWood is a hard, fibrous tissue found in many trees. It has been used for hundreds of thousands of years for both fuel and as a construction material. It is an organic material, a natural composite of cellulose fibers embedded in a matrix of lignin which resists compression...
. Although these artificial fibers were discovered in the mid-nineteenth century, successful modern manufacture began much later (see the dates below).
NylonNylon is a generic designation for a family of synthetic polymers known generically as polyamides, first produced on February 28, 1935, by Wallace Carothers at DuPont's research facility at the DuPont Experimental Station...
, the first synthetic fiber, made its debut in the
United StatesThe United States of America is a federal constitutional republic comprising fifty states and a federal district...
as a replacement for
silkSilk is a natural protein fiber, some forms of which can be woven into textiles. The best-known type of silk is obtained from the cocoons of the larvae of the mulberry silkworm Bombyx mori reared in captivity...
, just in time for
World War IIWorld War II, or the Second World War , was a global conflict lasting from 1939 to 1945, involving most of the world's nations—including all of the great powers—eventually forming two opposing military alliances: the Allies and the Axis...
rationing. Its novel use as a material for women's stockings overshadowed more practical uses, such as a replacement for the silk in
parachuteA parachute is a device used to slow the motion of an object through an atmosphere by creating drag, or in the case of ram-air parachutes, aerodynamic lift. Parachutes are usually made out of light, strong cloth, originally silk, now most commonly nylon...
s and other
militaryA military is an organization authorized by its greater society to use lethal force, usually including use of weapons, in defending its country by combating actual or perceived threats. The military may have additional functions of use to its greater society, such as advancing a political agenda e.g...
uses.
Common synthetic fibers include:
- Rayon
Rayon is a manufactured regenerated cellulose fiber. Because it is produced from naturally occurring polymers, it is neither a truly synthetic fiber nor a natural fiber; it is a semi-synthetic or artificial fiber. Rayon is known by the names viscose rayon and art silk in the textile industry...
(1910) (artificial, not synthetic)
- Acetate
Cellulose acetate , first prepared in 1865, is the acetate ester of cellulose. Cellulose acetate is used as a film base in photography, as a component in some adhesives, and as a frame material for eyeglasses; it is also used as a synthetic fiber and in the manufacture of cigarette filters and...
(1924) (artificial, not synthetic)
- Nylon
Nylon is a generic designation for a family of synthetic polymers known generically as polyamides, first produced on February 28, 1935, by Wallace Carothers at DuPont's research facility at the DuPont Experimental Station...
(1939)
- Modacrylic
A modacrylic is a synthetic copolymer. Modacrylics are soft, strong, resilient, and dimensionally stable. They can be easily dyed, show good press and shape retention, and are quick to dry. They have outstanding resistance to chemicals and solvents, are not attacked by moths or mildew, and are...
(1949)
- Olefin
Olefin fiber is a synthetic fiber made from a polyolefin, such as polypropylene or polyethylene. It is used in wallpaper, ropes, and vehicle interiors....
(1949)
- Acrylic
Acrylic fibers are synthetic fibers made from a polymer with an average molecular weight of ~100,000, about 1900 monomer units. To be called acrylic in the U.S, the polymer must contain at least 85% acrylonitrile monomer. Typical comonomers are vinyl acetate or methyl acrylate...
(1950)
- Polyester
Polyester is a category of polymers which contain the ester functional group in their main chain. Although there are many polyesters, the term "polyester" as a specific material most commonly refers to polyethylene terephthalate...
(1953)
- Carbon fiber
Carbon fiber, alternatively graphite fiber, carbon graphite or CF, is a material consisting of fibers about 5–10 μm in diameter and composed mostly of carbon atoms. The carbon atoms are bonded together in crystals that are more or less aligned parallel to the long axis of the fiber...
(1968)
Specialty synthetic fibers include:
- Vinyon
Vinyon is a synthetic fiber made from polyvinyl chloride. In some countries other than the United States, vinyon fibers are referred to as polyvinyl chloride fibers. It can bind non-woven fibers and fabrics. It was invented in 1939....
(1939)
- Saran
Saran is the trade name for a number of polymers made from vinylidene chloride , along with other monomers. The main advantage of Saran film is its very low permeability to water vapor, flavor and aroma molecules, and oxygen compared with other plastics...
(1941)
- Spandex
Spandex or elastane is a synthetic fibre known for its exceptional elasticity. It is strong, but less durable than natural Latex, its major non-synthetic competitor. It is a polyurethane-polyurea copolymer that was co-invented in 1959 by chemists C. L. Sandquist and Joseph Shivers at DuPont's...
(1959)
- Vinalon
Vinylon is a synthetic fiber produced from polyvinyl alcohol, using anthracite and limestone as raw materials. Vinalon was first developed in 1939 by Japanese scientist, Ichiro Sakurada, Yi Sung-ki [Lee. S.or Ri.Sung.Gi.] and H. Kawakami Production of this fiber was delayed for World War II. The...
(1939)
- Aramid
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 ballistic composites, in bicycle tires, and as an asbestos substitute. The name is a portmanteau of "aromatic polyamide"...
s (1961) - known as NomexNomex is a registered trademark for flame resistant meta-aramid material developed in the early 1960s by DuPont and first marketed in 1967.- Properties:...
, KevlarKevlar is the registered trademark for a para-aramid synthetic fiber, related to other aramids such as Nomex and Technora. Developed at DuPont in 1965, this high strength material was first commercially used in the early 1970s as a replacement for steel in racing tires...
and TwaronTwaron is the brandname of Teijin Aramid for a para-aramid. It is a heat-resistant and strong synthetic fibre developed in the early 1970s by the Dutch company AKZO, division Enka, later Akzo Industrial Fibers. The research name of the para-aramid fibre was originally Fiber X, but it was soon...
- Modal
Modal is a cellulose fiber made by spinning reconstituted cellulose, often from beech trees. It is about 50% more hygroscopic per unit volume than cotton. It takes dye like cotton and is color-fast when washed in warm water. Modal is a kind of rayon.Textiles made from modal are resistant to...
(1960's)
- Dyneema/Spectra (1979)
- PBI
Polybenzimidazole fiber is a synthetic fiber with a very high melting point that also does not readily ignite, because of its exceptional thermal and chemical stability. The U.S...
(Polybenzimidazole fiber) (1983)
- Sulfar
Polyphenylene sulfide is an organic polymer consisting of aromatic rings linked with sulfides. Synthetic fiber and textiles derived from this polymer are known to resist chemical and thermal attack. PPS is used to make filter fabric for coal boilers, papermaking felts, electrical insulation,...
(1983)
- Lyocell
Lyocell is a regenerated cellulose fiber made from dissolving pulp . It was first manufactured in 1987 by Courtaulds Fibres UK at their pilot plant S25...
(1992) (artificial, not synthetic)
- PLA (2002)
- M-5
M5 fiber is a high-strength synthetic fiber first developed by Dr. Doetze Sikkema and his team at the Dutch chemical firm Akzo Nobel...
(PIPD fiber)
- Orlon
- Zylon
Zylon is a trademarked name for a range of thermoset liquid crystalline polyoxazole...
(PBO fiber)
- Vectran
Vectran is a manufactured fibre, spun from a liquid crystal polymer created by Celanese Acetate LLC and now manufactured by Kuraray Co., Ltd. Chemically it is an aromatic polyester produced by the polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2-carboxylic acid.- Properties...
(TLCP fiber) made from Vectra LCP polymer
- Derclon used in manufacture of rugs
Other synthetic materials used in fibers include:
- Acrylonitrile
Acrylonitrile is the chemical compound with the formula C3H3N. This pungent-smelling colorless liquid often appears yellow due to impurities. It is an important monomer for the manufacture of useful plastics. In terms of its molecular structure, it consists of a vinyl group linked to a nitrile...
rubber (1930)
Modern fibers that are made from older artificial materials include:
- Glass fiber (1938) is used for:
- industrial, automotive, and home insulation (glass wool
Glass wool or fiberglass insulation is an insulating material made from fiberglass, arranged into a texture similar to wool. Glass wool is produced in rolls or in slabs, with different thermal and mechanical properties....
)
- reinforcement of composite material
Composite materials, often shortened to composites or called composition materials, are engineered or naturally occurring materials made from two or more constituent materials with significantly different physical or chemical properties which remain separate and distinct at the macroscopic or...
s (glass-reinforced plasticFiberglass , is a fiber reinforced polymer made of a plastic matrix reinforced by fine fibers of glass. It is also known as GFK ....
, glass fiber reinforced concreteGlass Fiber Reinforced Concrete is a type of fiber reinforced concrete. Glass fiber concretes are mainly used in exterior building façade panels and as architectural precast concrete.-Composition:...
)
- specialty papers in battery
An electrical battery is one or more electrochemical cells that convert stored chemical energy into electrical energy. Since the invention of the first battery in 1800 by Alessandro Volta and especially since the technically improved Daniell cell in 1836, batteries have become a common power...
separators and filtration
- Metallic fiber
Metallic fibers are manufactured fibers composed of metal, plastic-coated metal, metal-coated plastic, or a core completely covered by metal. Gold and silver have been used since ancient times as yarns for fabric decoration. More recently, aluminum yarns, aluminized plastic yarns, and aluminized...
(1946) is used for:
- adding metallic properties to clothing
Clothing refers to any covering for the human body that is worn. The wearing of clothing is exclusively a human characteristic and is a feature of nearly all human societies...
for the purpose of fashionFashion, a general term for a currently popular style or practice, especially in clothing, foot wear, or accessories. Fashion references to anything that is the current trend in look and dress up of a person...
(usually made with composite plastic and metal foils)
- elimination and prevention of static charge build-up
- conducting electricity
Electricity is a general term encompassing a variety of phenomena resulting from the presence and flow of electric charge. These include many easily recognizable phenomena, such as lightning, static electricity, and the flow of electrical current in an electrical wire...
to transmit information
- conduction of heat
In physics and thermodynamics, heat is energy transferred from one body, region, or thermodynamic system to another due to thermal contact or thermal radiation when the systems are at different temperatures. It is often described as one of the fundamental processes of energy transfer between...
In the horticulture industry synthetics are often used in soils to help the plants grow better. Examples are:
- expanded polystyrene flakes
- urea-formaldehyde foam resin
- polyurethane foam
- phenolic resin foam
Industry structure
During the last quarter of the 20th century, the Asian share of global output of synthetic fibers doubled to 65 per cent.
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