Polyester Fibers

Prepared by:
MUHAMMAD FIAZ
06-NTU-122
(C)
Definition
The name "polyester" refers to the linkage of
several monomers (esters) within the fiber. Esters
are formed when alcohol reacts with a carboxylic
acid.
Definition

Polyester fiber is a " manufactured

fiber in which the fiber forming
substance is any long chain synthetic
polymer composed at least 85% by
weight of an ester of a dihydric
alcohol (HOROH) and terephthalic
acid (p-HOOC-C6H4COOH)“.
Introduction

The first polyester fiber was Terylene.

In 1946 second polyester fiber
prepared was Dacron.
In 1958 another polyester fiber called
Kodel was developed by Eastman.
Introduction

Today, polyester is still widely

regarded as a "cheap, uncomfortable"
fiber, but even now this image is
slowly beginning to change with the
emergence of polyester luxury fibers
such as polyester micro fiber.
Process
Most polyesters are made from petroleum
from which the constituent acids and
alcohols are derived.
The types of processes that manufacturers
use vary, and little is known about specific
manufacturing processes, because the
companies want to keep them a secret in
order to remain competitive.
Process
1) Polymerization
Polyethylene Teraphthalate (PET) is
a condensation polymer and is
industrially produced by either
terephthalic acid or dimethyl
terephthalate with ethylene glycol.
A. Terephthalic Acid (PTA), produced
directly from p-xylene with bromide-
controlled oxidation.
Process
1) Polymerization
B. Dimethyl Terephthalate (DMT), made in
the early stages by esterification of
terephthalic acid. However, a different
process involving two oxidation and
esterification stages now accounts for
most DMT.
C. Ethylene Glycol (EG) initially generated
as an intermediate product by oxidation
of ethylene. Further ethylene glycol is
obtained by reaction of ethylene oxide
with water.
Process

2) Spinning
Polyester is a "melt spun" fiber, which
means that it is heated, extruded through
the spinnerets, and cools upon hitting the
air. From there it is wound around
cylinders.
Process

3) Drawing

To produce uniform PET, the drawing

process is carried out at temperature
above the glass transition temperature (80-
90oC) with draw ratios (3:1-6:1)
PROCESS
Variations on the Basic Polyester

Different fibers can be created by doing one or more of

the following:
Adding a delusterant (dulling agent) -
Polyester is a naturally bright fiber, but can be
made dull or semi-dull by the addition of a TiO2.
Changing the shape of the holes in the spinneret
The simplest and most common shape is a circle,
but by changing the shape of the spinneret,
square, oval, and bean-shaped fibers can be
formed. One can even create a hollow fiber. The
different shapes affect the hand and strength of
the fiber.
Variations on the Basic Polyester

Drawing out the fiber to five times its

original length is normal, but polyester
can be stretched even further. Drawing it
out more than normal may also affect the
strength, elasticity, and dye-ability.
Adding dye stuffs
In its natural state, polyester is a slightly
transparent off-white. Adding dye stuffs at
the manufacturing stage can create
brilliant colors like electric blue and
atomic red.
Variations on the Basic Polyester

Crimping
When the fiber is drawn out it is long and
smooth. Crimping can give the fiber more
texture and bulk and can increase its
insulation properties, as well as its
elasticity. Another word for this is
texturizing.
STRUCTURAL COMPOSITION OF PET

PET is attributed to the benzene rings in the

polymer chain. The aromatic character leads to
chain stiffness.

Polyester fibers may be considered to be

composed of crystalline, oriented semi crystalline
and noncrystalline (amorphous) regions.

Stabilization distances between atoms in

neighboring molecules are usually van der Waals
contact distances.
STRUCTURAL COMPOSITION OF PET

The cohesion of PET chains is a result of

van der Waals interactions, caused by
induced dipole interaction and dispersion
forces among the chains

The unusually high melting point of PET

(compared to aliphatic polyesters) is not
the result of any unusual intermolecular
forces, but is attributed to ester linkages.
STRUCTURAL COMPOSITION OF PET

The interactive forces create inflexible tight

packing among macromolecules, but the limited
flexibility in the macromolecule is mainly due to the
ethylene group.

A number of basic structural models are required

to represent the different states of the fiber:
amorphous (no orientation) after extrusion,
amorphous (no orientation) after cold drawing,
crystalline orientation after thermal treatment and
after hot drawing, stretching and annealing.
Crystallinity of Polyester Fiber

Density DSC Measurements

Gradient
Fiber Type Density (g/cc) Crystallinity Tg(oC) Tm (oC) ∆H Crystallinity
Base Fibers (%) (Cal/g) (%)

A 1.3803 41.22 154.3 251.3 17.19 51.38

B 1.3584 45.80 161.7 254.6 16.61 49.65

C 1.3809 41.73 152.9 255.8 15.29 45.73

D 1.3871 47.34 161.0 255.5 15.40 46.03

E 1.3825 43.71 175.9 257.4 16.41 49.05

Physical properties
strong
resistant to stretching and shrinking
resistant to most chemicals
quick drying
crisp and resilient when
wet or dry
wrinkle resistant
mildew resistant
abrasion resistant
able to retain heat-set pleats and creases
easily washed
Mechanical Properties
An increase of molecular weight further increases
the tensile properties, modulus, and elongation.

High tenacity filament and staple fiber curve (A and

B) have very high breaking strengths and moduli,
but relatively low elongations.

Partially oriented yarn (POY) and spun filament

yarns, exhibit low strength but very high elongation
(curve E).
Mechanical Properties
Typical stress strain
curve for PET fibers.
A-High tenacity filament
B-High tenacity staple
C-regular tenacity filament
D-regular tenacity staple
Mechanical Properties
When exposing PET fiber to repeated
compression (for example, repeated
bending), so-called kink bands start to
form, finally resulting in breakage of the
kink band into a crack.

If relaxation of stress and strain in the

oriented fiber is allowed to occur through
shrinkage during fiber manufacture, then
shrinkage at the textile processing stage is
reduced and initial modulus is lowered.
Mechanical Properties
It recovers well from stretch, compression,
bending, and shear because of its relatively high
initial modulus

Reducing the molecular weight, which affects the

abrasion resistance; flex life, and breaking
strength, results in a decrease in pilling tendency
of PET fiber.

The tighter the packing of molecular chains, the

stiffer and more mechanically resistant the fiber is.
Physical Properties of Polyester
Fibers
Filament yarn Staple and tow

Property Regular High tenacityb Regular High tenacityd

tenacitya tenacityc
breaking 0.35-0.5 0.62-0.85 0.35-0.47 0.48-0.61
tenacity,e N/tex
breaking 24-50 10-20 35-60 17-40
elongation
elastic recovery at 88-93 90 75-85 75-85
5% elongation, %

initial modulus, 6.6-8.8 10.2-10.6 2.2-3.5 4.0-4.9

N/texf
specific gravity 1.38 1.39 1.38 1.38

Moisture regian, 0.4 0.4 0.4 0.4

%
Melting 258-263 258-263 258-263 258-263
temperature, oC
Mechanical Properties

Crimp stability of the fiber can be

improved with an increase in heating
temperature

crimp compression of the fiber can be

decreased by increasing draw ratio
when the fiber is produced.
CHEMICAL PROPERTIES
Polyester fibers have good resistance to
weak mineral acids, even at boiling
temperature, and to most strong acids at
room temperature.

Hydrolysis is highly dependent on

temperature. Thus conventional PET fibers
soaked in water at 70oC for several weeks
do not show a measurable loss in strength,
but after one week at 100oC, the strength
is reduced by approximately 20%.
CHEMICAL PROPERTIES
Polyesters are highly sensitive to bases
such as sodium hydroxide and
methylamine, which serve as catalysts in
the hydrolysis reaction.

alkaline attack is sometimes used to modify

the fabric aesthetics during the finishing
process. The porous structures produced
on the fiber surface by this technique
contribute to higher wettability and better
wear properties
CHEMICAL PROPERTIES
Polyester displays excellent resistance to oxidizing
agents, such as conventional textile bleaches, and
is resistant to cleaning solvents and surfactants.

Concentrated solutions of benzoic acid and o-

phenylphenol have a swelling effect.

PET is both hydrophobic and oleophilic. The

hydrophobic nature imparts water repellency and
rapid drying. But because of the oleophilic
property, removal of oil stains is difficult.
CHEMICAL PROPERTIES
polyester fibers have a low moisture regain
of around 0.4%, which contributes to good
electrical insulating properties even at high
temperatures.

The tensile properties of the wet fiber are

similar to those of dry fiber.

The low moisture content, however, can

lead to static problems that affect fabric
processing and soiling.
OPTICAL PROPERTIES
PET has optical characteristics of many
thermoplastics, providing bright, shiny
effects desirable for some end uses, such as
silk-like apparel.

Recently developed polyester microfiber with

a linear density of less than 1.0 denier per
filament (dpf), achieves the feel and luster of
natural silk.
DYEING PROPERTIES
Because of its rigid structure, well-
developed crystallinity and lack of reactive
dyesites, PET absorbs very little dye in
conventional dye systems.

Polyester fibers are therefore dyed almost

exclusively with disperse dyes.
DYEING PROPERTIES
Third monomer
Polymerizing a third monomer, such as dimethyl
ester, has successfully produced a cationic dyeable
polyester fiber into the macro-molecular chain.

The third monomer make the structure of cationic

dyeable polyester less compact than that of normal
PET fibers. The disturbed structure is good for the
penetration of dyes into the fiber.

The disadvantage of adding a third monomer is the

decrease of the tensile strength.
DYEING PROPERTIES
Low temperature (40C) process
This method employs a disperse dye in a
microemulsion of a small proportion of alkyl
halogen and phosphoglyceride.

The main advantage of this method is low

temperature processing.

The environmental problem that is

produced by using toxic carriers.
DYEING PROPERTIES
Plasma technique
Spun bond PET nonwoven webs have been
treated by (SO2+O2) plasma and (N2+H2+He)
plasma.

Results show that spun bond PET nonwovens web

can be colored by conventional water-soluble acid
dyes.

Plasma techniques open new avenues for

coloring PET fabrics and are sure to be more
evident in the coloring of polyester fibers in the
future.
Other Properties
Polyester fibers display good resistance to
sunlight but long-term degradation appears to
be initiated by ultraviolet radiation.

Although PET is flammable, the fabric usually

melts and drops away instead of spreading
the flame.

Polyester has good oxidative and thermal

resistance.
Other Properties

the resistance of polyester fibers to

mildew, aging and abrasion is
excellent.

Molds, mildew and fungus may grow

on some of the lubricants or finishes,
but do not attack the fiber.
Applications
Because of their many desirable qualities,
polyester fibers and fabrics have many uses.

1) Polyester is often used in outerwear because of

its high tenacity and durability. It is a strong fiber
and consequently can withstand strong and
repetitive movements.

2) Its hydrophobic property makes it ideal for

garments and jackets that are to be used in wet
or damp environments - coating the fabric with a
water-resistant finish intensifies this effect.
Applications
3) Since polyester can be molded into
almost any shape, certain insulating
properties can be built-in to the fiber. One
method is to create hollow fibers.

4) One method is to create hollow fibers,

This process traps air inside the fiber
which is then heated by the body. The
warm air stays inside and helps warm the
body in cool weather.
Applications
5) A second method is to use crimped
polyester in a fiberfill product. The crimp
helps to keep in warm air.

6) Polyester is used in pants, shirts, suits,

and bed sheets either by itself or as a
blend, because of its wrinkle-resistant
property and its ability to retain its shape.
Since these garments are frequently worn
and washed, its stain-resistance and
durability are also desirable.
Applications

7) Polyester also has industrial uses as well,

such as carpets, filters, synthetic artery
replacements, ropes, and films.
Applications
Apparel
For every form of clothing
Home furnishing
carpets, curtains, draperies, sheets and
pillow cases, wall coverings and upholstery
Other
fiberfill for various products; automobile
upholstery, fire hose, power belting, ropes
and nets, sewing thread, tire cord, sails, v-
belts, floppy disk liners
Grades
POY yarns
flat yarn
textured yarn
airtextured yarn
high tenacity
monofilament
staple fibers
cut flock
tow
spun yarns
Making Yarns
After the fiber itself is created, it is made into
a yarn. There are two types of polyester
yarns: filament and spun.

Filament yarns are made by taking the

single polyester filaments, grouping them
together and then twisting or air-entangling
them to make them workable. A
monofilament yarn has just one, single
polyester fiber that is usually not twisted
Making Yarns
Spun yarns are produced in much the
same way as a cotton or wool yarn is
produced. The long filaments are fist cut
into short pieces called staple. These are
then combined together and spun to create
a yarn made up of thousands of short
filaments.
Blends
At this stage, polyester can also be combined
with other fibers to produce a variety of
effects.

Polyester and cotton is probably the most

famous and popular blend. The polyester
helps the fabric retain its shape and resist
stains and wrinkles. The cotton makes the
fabric more absorbent and comfortable.
Blends
Polyester is combined with wool to give it
wrinkle-resistance and shape retention in all
kinds of weather. Since polyester is stronger
than wool, it increases the durability and life of
the fabric. The wool contributes good draping
characteristics and elasticity.
Polyester and rayon is another popular blend
fabric. Here again the polyester makes the fabric
more resilient and durable, and helps it keep its
shape. The rayon adds a different texture, has a
good hand, is good for draping, and is more
absorbent.
Blends
Polyester and nylon produce a strong fabric
because of nylon's strength and abrasion
resistance and polyester's wrinkle-free properties.
This combination produces a yarn that is strong,
durable, stable, easy to launder, and resistant to
mildew and insects. Problems with this blend,
however, are that pilling may occur, and it does
not have a very nice hand. Furthermore, since
neither nylon nor polyester is very absorbent, the
fabric may feel wet and clammy in warm or humid
weather.
Weaving

After the yarns are made, they are shipped

out to textile mills to be woven into fabric.
Polyester can be made into both woven
and knitted fabrics (such as the infamous
double-knit!)
Finishing Processes
Finally, after the fabric is made, one or more of
the following finishing processes is often used
to improve the quality of the fabric:
Heat setting--creates a permanent shape

Singeing--improves the hand, reduces pilling,

and increases smoothness

Anti-static finish--reduces static electricity

Finishing Processes
Water and stain repellency--increases comfort
and makes it easier to clean; also used for
rainwear

Resin finishes--increases ease of care

Calendaring--increases smoothness and

reduces pilling

Embossing--creates a design and/or luster