Synthetic Fibres : Nylon, polyester, acrylic, polyolefin

308 Pages·2004·2.6 MB·English

by  J.E. McIntyre

Synthetic fibres: nylon, polyester, acrylic, polyolefin
Other titles in the Woodhead Publishing Limited series on fibres, published in
association with The Textile Institute:
Series Editor: Professor J. E. McIntyre
Bast and other plant fibres
High-performance fibres
Regenerated cellulose fibres
Silk, mohair, cashmere and other luxury fibres
Smart fibres, fabrics and clothing
Synthetic fibres:
nylon, polyester,
acrylic, polyolefin
Edited by J. E. McIntyre
CRC Press
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Contents
Contributor contact details viii
1 Historical background 1
J. E. McINTYRE, formerly University of Leeds, UK
1.1 Introduction 1
1.2 Fibres from chain-growth polymers 2
1.3 Fibres from step-growth polymers 8
1.4 Elastomeric fibres 12
1.5 Brief overview 14
1.6 References 15
2 Nylon fibres 20
A. F. RICHARDS, formerly Bolton Institute, UK
2.1 Introduction 20
2.2 Chemical structures 21
2.3 Polymerisation 23
2.4 Fibre production 33
2.5 Fibre properties 44
2.6 Fibre modification 72
2.7 Coloration 80
2.8 Applications 84
2.9 Recycling 87
2.10 References 88
v
vi Contents
3 Polyester fibres 95
A. J. EAST, Brooklake Polymers, USA
3.1 Introduction 95
3.2 Brief history of polyesters 96
3.3 PET polymer: raw materials, intermediates, polymer 100
synthesis and polymer properties
3.4 Cyclohexanedimethanol polyesters 111
3.5 Poly(butylene terephthalate) (PBT) 115
3.6 Poly(trimethylene terephthalate) (PTT or PPT) 117
3.7 Biodegradable polyester fibres 123
3.8 Melt-spinning polyester fibres and associated processing 129
3.9 Modification of polyester fibres 139
3.10 Dyeing polyesters 146
3.11 Bicomponent fibres and microfibres 151
3.12 World markets, future trends and conclusion 155
3.13 Acknowledgments 157
3.14 References 157
4 Acrylic fibres 167
R. COX, Acordis Acrylic Fibres, UK
4.1 Introduction 167
4.2 Chemical intermediates 168
4.3 Polymerisation techniques 171
4.4 Fibre production techniques 182
4.5 Physical properties and structure of fibres 199
4.6 Chemical variants 210
4.7 Fibre variants 222
4.8 End-use survey 225
4.9 References 231
5 Polyolefin fibres 235
R. R. MATHER, Heriot-Watt University, UK
5.1 Introduction 235
5.2 Molecular configuration 238
5.3 Production of polyolefins 238
5.4 Polyolefin structures 244
5.5 Fibre production 247
5.6 Additives 253
5.7 Coloration of polyolefin fibres 260
Contents vii
5.8 Properties of PP and PE fibres 261
5.9 Hard-elastic fibres 262
5.10 Processing–structure–property relationships 263
5.11 Applications 273
5.12 Recycling 278
5.13 Future trends 279
5.14 Conclusion 286
5.15 Acknowledgment 287
5.16 References 287
Index 293
Contributor contact details
Chapter 1 Chapter 4
Professor J. E. McIntyre Mr R. Cox
3 Rossett Gardens Acordis Acrylic Fibres
Harrogate HG2 9PP Acordis UK Ltd
UK Westcroft
Saint Street
Email: [email protected]
Bradford BD7 4AD
Chapter 2 UK
Dr A. F. Richards
Tel: [phone]
Greenacre
Fax: [phone]
Ribchester Road
Email: [email protected]
Clayton Le Dale
Blackburn BB1 9EE
UK Chapter 5
Tel: [phone]
Dr R. R. Mather
Email: [email protected]
School of Textiles
Heriot-Watt University
Chapter 3
Netherdale
Dr A. J. East Galashiels TD1 3HF
62 Niles Avenue UK
Madison
NJ 07940 2344 Email: [email protected]
USA
Email: [email protected]
viii
1
Historical background
J. E. McINTYRE
Formerly University of Leeds, UK
1.1 Introduction
This chapter reviews the early development of synthetic fibres, which are defined1
by the International Organization for Standardization (ISO) as fibres
manufactured from polymers built up from chemical elements or compounds, in
contrast to fibres made from naturally occurring fibre-forming polymers. The
definition excludes fibres made from regenerated cellulose, such as viscose rayon
and cuprammonium rayon, and from cellulose esters, such as secondary cellulose
acetate and cellulose triacetate. These fibres manufactured from cellulose became
established commercially many years before the first synthetic fibres were
discovered and developed. There was therefore quite a considerable amount of
information already available to the developers of fibres from new polymeric
materials about the production of fibres from solutions of high polymers by
extrusion into non-solvents, i.e. by wet-spinning, and into evaporative atmos-
pheres, i.e. by dry-spinning, and also about filament orientation by stretching and
about subsequent downstream handling. There was, however, only a very limited
understanding of the nature of polymers and of their macromolecular structure and
synthesis.
A major step forward in developing this understanding was taken in the 1920s,
when it was convincingly demonstrated, notably by Hermann Staudinger at the
Technische Hochschule in Zürich, that polymers were not colloidal assemblies of
molecules of low molecular weight, as many believed, but consisted of molecules
of high molecular weight. Staudinger was awarded the Nobel Prize for chemistry
in 1953 for his work on this subject. A major factor in convincing the chemical
community was work on polymer synthesis directed by W. H. Carothers in the
early 1930s at the Experimental Station of the DuPont company in Wilmington,
Delaware.
The terms addition polymerisation and condensation polymerisation were
introduced by Carothers.2 Addition polymerisation was defined as the chemical
union of many similar molecules without the elimination of simpler molecules,
and condensation polymerisation as the chemical union of many similar molecules
1
2 Synthetic fibres: nylon, polyester, acrylic, polyolefin
with the elimination of simpler molecules. Carothers recognised and stated that
some polymer structures could be made by either polyaddition or polycondensation
processes. Consequently the terms addition polymer and condensation polymer
should strictly be applied only to samples of known polymerisation history.
An alternative method of classification that depends on the nature of the
mechanism of growth of the polymer divides polymerisation reactions into those
exhibiting either chain-growth or step-growth mechanisms. Most chain-growth
polymerisations are addition polymerisations, and most step-growth
polymerisations are condensation polymerisations, but not all. For example,
stepwise polymerisations without elimination of a simple molecule, such as the
formation of a polyurethane, (–OROOCNHR′NHCO–), from a diol, HOROH,
n
and a di-isocyanate, OCNR′NCO, cannot be classed as condensation
polymerisations. In the ensuing discussion of the early historical development of
synthetic fibre-forming polymers, polymers normally formed by chain-growth
polymerisation will be considered before those formed by step-growth
polymerisation.
1.2 Fibres from chain-growth polymers
1.2.1 Chlorofibres
1.2.1.1 European development3
Research in Germany during the period 1911–1913 by Klatte at Chemische Fabrik
Griesheim Elektron led to the definition of conditions for reacting acetylene with
acids to form vinyl compounds, particularly vinyl chloride and vinyl acetate.
Klatte’s work on the polymerisation of these products formed the basis of an
application on 4 July 1913 for a patent4 covering the formation of fibres from
poly(vinyl chloride) (PVC). Subsequent workers, such as Rein,5 describe Klatte’s
work and the filing of this patent as the beginning of the story of synthetic fibres.
The polymer is shown to be soluble in hot chlorobenzene, and useful (künstliche)
fibres are said to be obtained directly by extrusion of the solution into a precipitat-
ing bath.4 A US patent,6 filed just under a year later and evidently a considerably
amplified equivalent of the patent originally filed in Germany, claims the produc-
tion of polymers from vinyl acetate, vinyl chloroacetate or vinyl chloride. The
formation of fibres from solutions of poly(vinyl chloride) by spinning a solution in
hot chlorobenzene into a precipitating bath is described, and the spinning of fibres
from poly(vinyl chloroacetate) and poly(vinyl acetate) from solvents such as
acetone is also included. Despite the examples, there are no specific claims to fibre
formation, and no industrial development of fibres ensued.
According to Bode,7 the first synthetic fibre was produced by Hubert at the
laboratories of IG Farben at Wolfen, north of Leipzig, from PVC. Work on this
topic had begun in the rayon laboratories at Wolfen in about 1928, and all the high