BGMEA University of Fashion & Technology (BUFT)

BGMEA University of Fashion & Technology

Course Title : Textile Testing & Quality Control-II

Course Code : TEX3105

Assignment Name: Zylon (PBO) Fiber

Submitted to: Submitted by:

Shafat Ahmed Bin Kamal ID :
Lecturer, 191-099-801
191-100-801
Department of TE, 191-108-801
BUFT 191-114-801

Submission Date :12/07/2021

 ZYLON (PBO) Fiber

Introduction :
Fiber and its properties are very important to the performance of the final textile products.
The textile fibers that are used for producing high performance products are increasing day by
day. These fibers and composites made from them gained rapid acceptance in a broad range
of technologies. This is because of their mechanical properties, outstanding abrasion
resistance, thermal resistance, chemical resistance and cut resistance; and so on. The concept
of high-performance fiber came into textile industries during 1950-1970’s. In the 21st century,
there are number of advancements took place and it will continue which will influence whole
textile world. Biotechnology, nanotechnology, fiber engineering and material science will plays
an important role for further development of fibers for next generation.
Zylon (PBO) is a one kind of high-performance fiber.(PBO) means Polybenzoxazole. Zylon PBO
Is called worlds strongest synthetic fiber. The fiber is difficult to manufacture and rather
expensive and thus only used for very demanding applications such as bullet proof vests and
expensive sporting goods. Zylon has an outstanding strength-to-weight ratio, even better than
carbon and aramid, and outstanding dimensional stability. Due to its fully aromatic structure,
it has excellent heat resistance, very low flammability, and good or excellent chemical
resistance to most organic solvents . Zylon is quite flexible and has a very soft hand, in spite
of its extremely high mechanical properties. It can be processed into various product forms,
such as continuous filament, staple fiber, spun yarn, woven and knitted fabrics, chopped fiber
and pulp. Zylon are excellent creep resistance, very good anti-cutting performance, minimal
temperature shrinkage, abrasion resistance close to para aramids, good mechanical fatigue
resistance.
Fiber types: Synthetic Fiber
IUPAC name: poly(p-phenylene-2,6-benzobisoxazole)
Commercial Name: Zylon
Brand: TOYOBO,Japan
Source: Aramid

Characteristics: Chemical resistant, High strength, Heat resistant, Tensile modulus.

End uses: Table Tennis Racket, Tennis Racket, Parachutes, Conductive textile, Body Armor,
Sports car body, Snowboard ,Skating Board, Artillery shell and so on .

History Of Zylon (PBO) Fiber:

There are many people who have helped make zylon possible, ranging from discovering new
ways to synthesize polymers to how fibers of these polymers are processed. Zylon began
being developed after the U.S Air Force Research Laboratory found success in the creation of
the rigid rod polymer Kevlar during the 1970s. They started investigating other rigid rod
polymers that could be stronger than Kevlar. The results of this investigation were PBO fibers.
Further research took place at SRI International and soon after at Dow Chemical Company.
Eventually leading to the Japan company Toyobo which commercializing PBO with the trade
name zylon in 1998. In 1980s an development ensures that Zylon is the worlds strongest man-
made fiber. Zylon (PBO) is also the first organic fiber whose cross-sectional strength
outperforms both steel and carbon fiber.

Manufacturer of zylon fiber

Types Of Zylon (PBO) Fiber:

There are two types of zylon fiber.

1. Zylon AS ( As Spun)

2. Zylon HM ( High Modulus)

Zylon AS:
Zylon AS shows highest tensile strength and tensile modulus among the all high performance
fiber. The tensile strength of Zylon AS is 5.8 GPa, tensile modulus 180 GPa, and elongation at
break 3.5%. The modulus increases substantially by heat treatment at 580 °C up to 280 GPa,
while elongation at break decreases to 2.5%. The decomposition temperature of Zylon AS is
similar as Zylon HM which is 650 degree centigrade. Zylon AS also shows a good chemically
resistance as compared with others

Zylon HM:
Zylon HM is another type of fiber. It shows the highest tensile strength and properties as compared
with Zylon AS , Carbon , Aramid and other fibers. This fiber also shows a good flame resistance and
thermal stability. The moisture regain of this fiber is 0.6% and the elongation at break of this fiber is
2.5%. It shows a similar heat resistivity as compared with Zylon AS. It shows some similar properties as
Zylon AS.

Basic Properties of zylon AS and zylon HM :

Molecular Structure of Zylon (PBO):

Chemical name of zylon PBO is poly(p-phenylene-2,6-benzobisoxazole).Zylon is produced from

the two monomers 4,6-diamino-1,3-benzenediol dihydrochloride and terephthalic acid.

poly(p-phenylene-2,6-benzobisoxazole)

Production Of Zylon (PBO):

Zylon is produced from the two monomers 4,6-diamino-1,3-benzenediol dihydrochloride

(DABDO) and terephthalic acid (TA). Zylon is a condensation polymer meaning it performs a
condensation reaction between the two monomers said above. For this reaction to take place
it requires 77% polyphosphoric acid at 60-80 degrees Celsius to allow 4,6-diamino-1,3-
benzenediol dihydrochloride to perform dehydrochlorination. Polyphosphoric acid is highly
concentrated (above 95%) phosphoric acid which due to the high concentration will
polymerize. Once dehydrochlorination is complete, P2O5 is then added and the temperature
is decreased to 50 degrees Celsius, this allows for polymerization to be between 82%-84%.

Spinning Of Zylon (PBO):

Since zylon has a lower decomposition temperature than melting point as well as very few
solvents it can be dissolved in, the polymer cannot use basic spinning by melting or by being
put in a solution and spinned as other polymers can. Instead the dry-jet wet-spinning method
is used with a solution of PBO dissolved in polyphosphoric acid. With pressure and heat this
solution is extruded through an air gap. It then enters a coagulating bath of usually room
temperature water. In order to obtain the fiber having high mechanical properties, the spin
draw ratio is very important. After the bath the polymer is washed, dried and heat treated.
The Heat treatment is most often carried out with the string under tension at a temperature
range between 500-700 degrees Celsius for several seconds to a few minutes. During this time
the string is in nitrogen. A string of zylon has now been created.
Schematic diagram of PBO spinning machine
Physical properties:
ZYLON(PBO fiber) is the next generation super fiber with strength and modulus almost
doubles that of p-Aramid fiber. ZYLON shows 100°C higher decomposition
temperature than p-Aramid fiber. The limiting oxygen index is 68, which is the highest
among organic super fibers.

There are two types of fibers, AS (as spun) and HM (high modulus). HM is different
from AS in modulus, moisture regain and etc.
Comparison of mechanical properties with other fibers:
ZYLON has the highest tensile strength and tensile modulus among high-
performance fibers.

Influence of twist on tensile properties

ZYLON is shipped with zero twist. A certain twist has to be applied in order to measure
its correct tensile strength. These figures show the influence of twist factor on tensile
strength and modulus for 555 dtex ZYLON® yarn. For different dtex yarns, optimum
twist level can be estimated by using twist factor. Twist factor is defined by the
following formula.Twist factor (TF) = 0.124 x (turns per inch) x (dtex)0.5
Creep Properties
ZYLON has superior creep resistance to p-Aramid fibers. (Creep means a non-
recoverable strain after prolonged static loading.) When a certain load is applied to
yarn, recoverable strain (initial strain) and non-recoverable strain are observed. For
ZYLON HM, non-recoverable strain after 100 hours under 50% of breaking load
(Safety factor (SF)=2) is less than 0.03%.

Thermal properties
Decomposition Temperature
ZYLON has a 100°C higher decomposition temperature than p-Aramid fibers. Thermal
gravimetric analysis charts in air and argon gas are shown below. The heating rate is
20°C/min
Isothermal weight loss
A significant difference of weight loss behavior is observed at 500°C between
ZYLON® and Aramid fibers.

Effect of temperature on strength and modulus

The relative strength of ZYLON decreases from room temperature to 500°C. ZYLON
retains 40% of the room temperature strength even at 500°C. The temperature
dependence of modulus is shown below. Even at 400°C, ZYLON retained 75% of
modulus at room temperature.
Flame resistance
ZYLON shows extremely high flame resistance. In a vertical flame test (JIS L1091 A-
4), char length is almost zero.

Light resistance
The strength of ZYLON decreases with exposure to sunlight. Light resistance of
ZYLON was evaluated using Xenon light weather-ometer. As shown below, the
strength decreases sharply at the initial stage of exposure. End products of ZYLON for
outdoor use have to be protected by covering materials. The residual strength of
ZYLON after 6 months exposure to daylight is about 35%.
ZYLON should be protected not only from ultraviolet light but also from visible light.
These data show strength retention after exposure to fluorescent lamp.

Chemical resistance

Organic mediums
ZYLON is stable with most of organic mediums.

Inorganic mediums
Exposure to strong acids causes strength losses

ZYLON is stable to alkaline at room temperature. NaClO (bleach) does not cause
strength loss for ZYLON at room temperature.
At higher temperatures, the strength of ZYLON AS staple fiber decreases in acid and
also in alkaline.
Moisture regain

The moisture regain of ZYLON at 20°C, 65%RH is 2.0% for AS and 0.6% for HM.

Chemical and Environmental Effects on Zylon ( PBO) :

*The strength retention of PBO fibers after prolonged high-temperature exposure is

greater in comparison with para-aramid fibers. Whilst the strength of PBO fibers is not
affected by being held at 300 degree Celcius in an inert atmosphere, exposure at 300
degree Celcius in air causes a reduction of 25% in strength.

*PBO-based Zylon AS and Zylon HM fibers display moisture adsorption of 2.0% and 0.6%
respectively. Even if PBO fibers are highly resistant to hydrolysis in comparison to para-
aramid fibers, the combination of humidity and high temperature can drastically impair
the tensile strength. Exposure to saturated steam for 50 h at 250C causes the strength to
decrease below 20% of its room temperature value.
 *PBO fibers are also very sensitive to UV and visible light. Exposure to UV radiation
induces sharp drops of the tensile strength in the initial stage . Similarly, a 1 month
exposure to two 35 W fluorescent lamps placed 150 cm from the sample resulted in a
reduction of the PBO fiber tensile strength to nearly 70% of it original value. On the other
hand, PIPD-based M5 fibers display very high resistance to visible and UV light. After
exposure to a Zenon lamp for 100 h, the tensile strength of M5 yarns remained
unchanged, whilst the tensile strength of Zylon yarns decreased by 35% .

*PBO fibers are generally highly resistant to chemicals at room temperature, but they are
quite sensitive to exposure to strong acids and bases at high temperature.

*The initial strength of zylon yarns lost over 20% of their initial tensile strength to elevated
temperature .

Applications Of Zylon(PBO):

Zylon is used in a number of applications throughout numerous industries. We can find zylon
in firefighter garments, safety gloves, bulletproof vests, and more. Here’s a brief list of some of
the most common uses of Zylon in manufacturing:

Protective Clothing:
Zylon’s high resistance to heat, flames, and puncturing makes it an ideal material for a number
of garments. We can find Zylon in protective firefighter clothing, safety gloves, and heat-
resistant garments.
Industrial Uses:
Zylon has a number of uses in the industrial sector. Zylon can be manufactured into heat-
resistant felt for a variety of applications. It can be used as a cable cover material for welding
machines (since it can protect cords from hot sparks). It can even be found in cement as a
reinforcing material.

Table Tennis Racket :

One use of zylon is in table tennis rackets. In a racket there are many layers of material that
make up the paddle and handle. In some rackets zylon is used in some of these layers as seen
in the picture above. Some of these layers can have carbon weaved through the zylon. Since
zylon is so strong and rigid the table tennis racket will bend less making more of the energy go
into the ball letting there be a greater maximum ball speed that is attainable.
Snowboard :
Zylon is uses in snowboards. As seen in the picture on the right there is strips of zylon inside
the board. These strips allow the board to be extremely strong however still flexible. Carbon is
another material used in snowboards however if it is used without zylon than the board would
break easily as carbon doesn't have as much elasticity.
Discontinued Body Armor:
Body armour has long been used to protect soldiers on the battlefield. From the use of
leather in the east to chain mail in the west, people never stopped seeking better personnel
protection. During the development of modern lightweight body armour, the aim was always
to develop lighter and stronger materials so that the advancement of performance could be
achieved at a reduced weight. The advent of synthetic fibres speeded up innovation in this
field.
Over the past few decades, efforts to design more effective protective body armour have
continued. Among recent innovations, materials such as PBO (p-phenylene-2,6-
benzobisoxazole) and M5® (polyhydroquinone-diimidazopyridine) are the most efficient
(however costly) way to improve body armour performance. Parallel to this approach, much
attention has also been paid to textile-based technologies. Development of optimum fabric
and panel structures enables more energy to be absorbed, leading to lower levels of blunt
trauma being impacted on the human torso. Research and development on ballistic impact
have greatly improved the performance, efficiency, and reliability of body armour, providing
more protection, mobility, and comfort to its wearers.
Sports car :
Polybenzobisoxazole (p-phenylene-2,6-benzobisoxazole) (PBO) is a rigid-rod isotropic crystal
polymer. Zylon is quite flexible and has a very soft hand, in spite of its extremely high
mechanical properties. Now a days sport cars body and other parts are manufactured by
zylon fiber. To meet revised technical requirements from the FIA, F1's sanctioning body,
engineers were required to make significant changes to the previous car's body and chassis,
including the addition of a thick pad of Zylon, to improve side impact protection.
Application based on Different form of PBO fiber:
 Chopped Fiber .
Reinforcement for gaskets .
Plastic reinforcement
 Staple Fiber
Heat resistant felt
Media for high temperature filtration

 Spun Yarn

Racing and riding suits .

Protective cloth for fire-fighting .
Heat and flame resistant welding apparel .
Cut and abrasion resistant fabrics (gloves and safety shoes)

 Continuous filament

Reinforcement for tires, belts, and hoses

Reinforcement for concrete and plastic .
Tension member for fiber optic cables .
High tension rope or cord
Ballistic vests and helmets
Yacht sailcloth .
High temperature filtration.

Conclusion:
Fiber and its properties are very important to the performance of the final textile products.
The textile fibers that are used for producing high performance products are increasing day by
day. These fibers and composites made from them gained rapid acceptance in a broad range
of technologies. PBO fibers are the successful result of a research programmer aimed at
designing, synthesizing and processing rigid-rod molecules into ordered polymer fibers with
exceptional mechanical properties. PBO shows very impressive tensile properties, its
performance under compression has been disappointing, and much work has been done in
various ways to correct the problem, without making much headway. The fibers are now being
commercialized by Toyobo Co. Ltd of Japan under the trade name Zylon. They are finding use
in a number of applications where they have benefited somewhat from the development of a
market for such materials through the exploitation of aramid fibers. PBO fibers have specific
(per unit weight) values of strength and stiffness in excess of all other materials and their
future appears to be very promising indeed.

Reference :

https://www.toyobo-global.com/seihin/kc/pbo/zylon-p/bussei-p/technical.pdf

http://www.formula1-dictionary.net/zylon.html?
fbclid=IwAR2ccGGyYXkbYv6HVjYO8WC_XaJDoXE9lhW6k0MYrOYMKoR9u8s8LbCACFg

https://www.aramid.com/zylon-pbo/

https://www.aramid.com/zylon-pbo/

https://www.toyobo-global.com/seihin/kc/pbo/zylon-p/bussei-p/technical.pdf

https://www.toyobo-global.com/seihin/kc/pbo/zylon_bussei.html

High-performance fibres By J W S Hearle.

Chapter-4 (Other high modulus-high tenacity (HM-HT) fibres from linear polymers)

https://polymerdatabase.com/Fibers/PBO.html?
fbclid=IwAR2zDfh3VdtFB1uDoROuZxRljvdoxL0WBi3vSojCtVxLQatTZIDji9kSxuw

https://www.sciencedirect.com/science/article/pii/B9780128126400000020

https://www.sciencedirect.com/science/article/pii/B9781782424659000069

https://www.fiberbrokers.com/technical-materials-recycling/all-about-zylon/