Acrylic fiber

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Acrylic yarn dyed with basic dyes Yarn hanks.jpg
Acrylic yarn dyed with basic dyes

Acrylic fibers are synthetic fibers made from a polymer (polyacrylonitrile) with an average molecular weight of ~100,000, about 1900 monomer units. For a fiber to be called "acrylic" in the US, the polymer must contain at least 85% acrylonitrile monomer. Typical comonomers are vinyl acetate or methyl acrylate. DuPont created the first acrylic fibers in 1941 and trademarked them under the name Orlon. [1] It was first developed in the mid-1940s but was not produced in large quantities until the 1950s. Strong and warm, acrylic fiber is often used for sweaters and tracksuits and as linings for boots and gloves, as well as in furnishing fabrics and carpets. It is manufactured as a filament, then cut into short staple lengths similar to wool hairs, and spun into yarn.

Contents

Modacrylic is a modified acrylic fiber that contains at least 35% and at most 85% acrylonitrile. Vinylidene chloride or vinyl bromide used in modacrylic give the fiber flame retardant properties. End-uses of modacrylic include faux fur, wigs, hair extensions and protective clothing.

Production

The polymer is formed by free-radical polymerization in aqueous suspension. The fiber is produced by dissolving the polymer in a solvent such as N,N-dimethylformamide (DMF) or aqueous sodium thiocyanate, metering it through a multi-hole spinneret and coagulating the resultant filaments in an aqueous solution of the same solvent (wet spinning) or evaporating the solvent in a stream of heated inert gas (dry spinning). Washing, stretching, drying and crimping complete the processing. Acrylic fibers are produced in a range of deniers, usually from 0.9 to 15, as cut staple or as a 500,000 to 1 million filament tow. End uses include sweaters, hats, hand-knitting yarns, socks, rugs, awnings, boat covers, and upholstery; the fiber is also used as "PAN" precursor for carbon fiber. Production of acrylic fibers is centered in the Far East, Turkey, India, Mexico, and South America, though a number of European producers still continue to operate, including Dralon and Fisipe. US producers have ended production (except for specialty uses such as in friction materials, gaskets, specialty papers, conductive, and stucco), though acrylic tow and staple are still spun into yarns in the USA. Former U.S. brands of acrylic included Acrilan (Monsanto), and Creslan (American Cyanamid). Other brand names that are still in use include Dralon (Dralon GmbH) and Drytex (Sudamericana de Fibras, S.A.).[ citation needed ] In the late 1950s, Courtaulds Ltd began investigating the production of an acrylic fiber later to be called "courtelle" by a process of solvent polymerisation. Methyl acrylate (6%) and acrylonitrile were polymerised in a 50% solution of sodium thiocyanate to produce a dope ready for spinning into a waterbath to produce "courtelle" fiber in various grades of denier. The sodium thiocyanate solution was reconcentrated and re-used. The reaction was a continuous process, with about 5% of reactants being recycled. This recycling process resulted in the build-up of pollutants in the process, as did the recycling of the solvent. A great deal of research in the chemical engineering laboratory in Lockhurst Lane, Coventry, and on the pre-production pilot plant at Little Heath overcame the recycling problems and resulted in the process becoming a commercial success at a new production plant in Grimsby.

Textile uses

Acrylic is lightweight, soft, and warm, with a wool-like feel. [2] It can also be made to mimic other fibers, such as cotton, when spun on short staple equipment. Some acrylic is extruded in colored or pigmented form; other is extruded in "ecru", otherwise known as "natural," "raw white," or "undyed." Pigmented fiber has the highest lightfastness. Its fibers are very resilient compared to both other synthetics and natural fibers. Some acrylic is used in clothing as a less expensive alternative to cashmere, due to the similar feeling of the materials. Some acrylic fabrics may fuzz or pill easily, though there are low-pilling variants. Acrylic takes color well, is washable, and is generally hypoallergenic. End-uses include socks, hats, gloves, scarves, sweaters, home furnishing fabrics, and awnings. Acrylic can also be used to make fake fur and to make many different knitted clothes.

As acrylic is a synthetic fiber, the larvae of clothes moths are unable to digest it. However, acrylic fibers that are blended with wool or soiled may be eaten as a consequence of having blended fibers. [3]

Acrylic is the "workhorse" hand-crafting fiber for crafters who knit or crochet; acrylic yarn may be perceived as "cheap" because it is typically priced lower than its natural-fiber counterparts, and because it lacks some of their properties, including softness and propensity to felt. The fiber requires heat to "relax" or set the shape of the finished garment, and it isn't as warm when wet as alternatives like wool. Some hand-knitters also complain that the fiber "squeaks" when knitted, or that it is painful to knit with because of a lack of "give" or stretch in the yarn. On the other hand, it is machine-washable and extremely color-fast. This makes it useful in certain items, like garments for babies, which require constant washing. However it is much more flammable than its natural fiber counterparts, so caution should be used when making items for babies and children.

Microplastic release

A team at Plymouth University in the UK spent 12 months analyzing what happened when a number of synthetic materials were washed at different temperatures in domestic washing machines, using different combinations of detergents, to quantify the microfibres shed. They found that acrylic was responsible for releasing nearly 730,000 tiny synthetic particles (microplastics) per wash, five times more than polyester-cotton blend fabric, and nearly 1.5 times as many as pure polyester. [4] [5] [6] [7] Research by ecologist Mark Browne showed synthetic fibre waste over coastlines at a global scale, with the greatest concentration near sewage outflows. Of the man-made material found on the shoreline, 85% were microfibers and matched the types of material (such as nylon and acrylic) used in clothing. [8]

See also

Related Research Articles

<span class="mw-page-title-main">Textile</span> Various fiber-based materials

Textile is an umbrella term that includes various fiber-based materials, including fibers, yarns, filaments, threads, different fabric types, etc. At first, the word "textiles" only referred to woven fabrics. However, weaving is not the only manufacturing method, and many other methods were later developed to form textile structures based on their intended use. Knitting and non-woven are other popular types of fabric manufacturing. In the contemporary world, textiles satisfy the material needs for versatile applications, from simple daily clothing to bulletproof jackets, spacesuits, and doctor's gowns.

<span class="mw-page-title-main">Yarn</span> Long continuous length of interlocked fibres

Yarn is a long continuous length of interlocked fibres, used in sewing, crocheting, knitting, weaving, embroidery, ropemaking, and the production of textiles. Thread is a type of yarn intended for sewing by hand or machine. Modern manufactured sewing threads may be finished with wax or other lubricants to withstand the stresses involved in sewing. Embroidery threads are yarns specifically designed for needlework. Yarn can be made of a number of natural or synthetic materials, and comes in a variety of colors and thicknesses. Although yarn may be dyed different colours, most yarns are solid coloured with a uniform hue.

<span class="mw-page-title-main">Rayon</span> Cellulose-based semi-synthetic fiber

Rayon, also called viscose and commercialised in some countries as sabra silk or cactus silk, is a semi-synthetic fiber, made from natural sources of regenerated cellulose, such as wood and related agricultural products. It has the same molecular structure as cellulose. Many types and grades of viscose fibers and films exist. Some imitate the feel and texture of natural fibers such as silk, wool, cotton, and linen. The types that resemble silk are often called artificial silk. It is used to make textiles for clothing and other purposes.

Synthetic fibers or synthetic fibres are fibers made by humans through chemical synthesis, as opposed to natural fibers that are directly derived from living organisms, such as plants or fur from animals. They are the result of extensive research by scientists to replicate naturally occurring animal and plant fibers. In general, synthetic fibers are created by extruding fiber-forming materials through spinnerets, forming a fiber. These are called synthetic or artificial fibers. The word polymer comes from a Greek prefix "poly" which means "many" and suffix "mer" which means "single units"..

<span class="mw-page-title-main">Polyacrylonitrile</span> Chemical compound

Polyacrylonitrile (PAN) is a synthetic, semicrystalline organic polymer resin, with the linear formula (CH2CHCN)n. Almost all PAN resins are copolymers with acrylonitrile as the main monomer. PAN is used to produce large variety of products including ultra filtration membranes, hollow fibers for reverse osmosis, fibers for textiles, and oxidized PAN fibers. PAN fibers are the chemical precursor of very high-quality carbon fiber. PAN is first thermally oxidized in air at 230 °C to form an oxidized PAN fiber and then carbonized above 1000 °C in inert atmosphere to make carbon fibers found in a variety of both high-tech and common daily applications such as civil and military aircraft primary and secondary structures, missiles, solid propellant rocket motors, pressure vessels, fishing rods, tennis rackets and bicycle frames. It is a component repeat unit in several important copolymers, such as styrene-acrylonitrile (SAN) and acrylonitrile butadiene styrene (ABS) plastic.

<span class="mw-page-title-main">Lyocell</span> Regenerated cellulose fiber made from dissolving pulp

Lyocell is a semi-synthetic fiber used to make textiles for clothing and other purposes. It is a form of regenerated cellulose made by dissolving pulp and dry jet-wet spinning. Unlike rayon made by some of the more common viscose processes, Lyocell production does not use carbon disulfide, which is toxic to workers and the environment. Lyocell was originally trademarked as Tencel in 1982.

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 nonallergenic. Among their uses are in apparel linings, furlike outerwear, paint-roller covers, scatter rugs, carpets, and work clothing and as hair in wigs.

<span class="mw-page-title-main">Dyeing</span> Process of adding color to textile products like fibers, yarns, and fabrics

Dyeing is the application of dyes or pigments on textile materials such as fibers, yarns, and fabrics with the goal of achieving color with desired color fastness. Dyeing is normally done in a special solution containing dyes and particular chemical material. Dye molecules are fixed to the fiber by absorption, diffusion, or bonding with temperature and time being key controlling factors. The bond between the dye molecule and fiber may be strong or weak, depending on the dye used. Dyeing and printing are different applications; in printing, color is applied to a localized area with desired patterns. In dyeing, it is applied to the entire textile.

<span class="mw-page-title-main">Textile manufacturing</span> The industry which produces textiles

Textile manufacturing is a major industry. It is largely based on the conversion of fibre into yarn, then yarn into fabric. These are then dyed or printed, fabricated into cloth which is then converted into useful goods such as clothing, household items, upholstery and various industrial products.

<span class="mw-page-title-main">Polyester</span> Category of polymers, in which the monomers are joined together by ester links

Polyester is a category of polymers that contain the ester functional group in every repeat unit of their main chain. As a specific material, it most commonly refers to a type called polyethylene terephthalate (PET). Polyesters include naturally occurring chemicals, such as in plants and insects, as well as synthetics such as polybutyrate. Natural polyesters and a few synthetic ones are biodegradable, but most synthetic polyesters are not. Synthetic polyesters are used extensively in clothing.

<span class="mw-page-title-main">Polar fleece</span> Insulating knitted polyester napped or pile fabric

Polar fleece is a soft fabric made from polyester that is napped and insulating.

<span class="mw-page-title-main">Blocking (textile arts)</span>

In knitting, crochet and other handmade textile arts, blocking is a final stage of handmade textile production that adjusts the shape and size of the finished piece. Not all pieces need blocking; however, blocking is standard for lace work and is not uncommon in sweaters, socks, and other solid projects. Through heat and moisture, blocking sets the stitches and standardizes the final dimensions, and may enhance the drape. Hand manufacture places natural stresses on fabrics that may result in deviations from its intended shape and size. Blocking is only effective on natural fibres but a technique called killing may be used on synthetic fibres to achieve an effect similar to blocking.

Olefin fiber is a synthetic fiber made from a polyolefin, such as polypropylene or polyethylene. It is used in wallpaper, carpeting, ropes, and vehicle interiors.

The manufacture of textiles is one of the oldest of human technologies. To make textiles, the first requirement is a source of fiber from which a yarn can be made, primarily by spinning. The yarn is processed by knitting or weaving, which turns yarn into cloth. The machine used for weaving is the loom. For decoration, the process of colouring yarn or the finished material is dyeing. For more information of the various steps, see textile manufacturing.

A staple fiber is a textile fiber of discrete length. The opposite is a filament fiber, which comes in continuous lengths. Staple length is a characteristic fiber length of a sample of staple fibers. A fiber is made up of natural substances and is known for being longer than it is wide. It is an essential criterion in yarn spinning, and aids in cohesion and twisting. Compared to synthetic fibers, natural fibers tend to have different and shorter lengths. The quality of natural fibers like cotton is categorized into staple length such as short, medium, long staple, and extra-long. Gossypium barbadense, one of several cotton species, produces extra-long staple fibers. The staple fibers may be obtained from natural and synthetic sources. In the case of synthetics and blends, the filament yarns are cut to a predetermined length.

<span class="mw-page-title-main">Finishing (textiles)</span> Manufacturing process

In textile manufacturing, finishing refers to the processes that convert the woven or knitted cloth into a usable material and more specifically to any process performed after dyeing the yarn or fabric to improve the look, performance, or "hand" (feel) of the finish textile or clothing. The precise meaning depends on context.

<span class="mw-page-title-main">Pill (textile)</span> Small ball of fibres adhering to the surface of a textile

A pill, colloquially known as a bobble, fuzzball, or lint ball, is a small ball of fibers that forms on a piece of cloth. Pill is also a verb for the formation of such balls.

Dimensional stability pertains to a fabric's ability to maintain its initial size and shape even after undergoing wear and care, which is a desirable property. Dimension stability in fabrics or Shrinkage is the change of dimensions in textile products when they are washed or relaxed. The change is always expressed relative to the dimensions before the exposure of washing or relaxing. Shrinkage is also called residual shrinkage and measured in percentage. The major cause of shrinkages is the release of stresses and strains introduced in manufacturing processes. Textile manufacturing is based on the conversion of fiber into yarn, yarn into fabric, includes spinning, weaving, or knitting, etc. The fabric passes through many inevitable changes and mechanical forces during this journey. When the products are immersed in water, the water acts as a relaxing medium, and all stresses and strains are relaxed and the fabric tries to come back to its original state.

Wet Processing Engineering is one of the major streams in Textile Engineering or Textile manufacturing which refers to the engineering of textile chemical processes and associated applied science. The other three streams in textile engineering are yarn engineering, fabric engineering, and apparel engineering. The processes of this stream are involved or carried out in an aqueous stage. Hence, it is called a wet process which usually covers pre-treatment, dyeing, printing, and finishing.

<span class="mw-page-title-main">Acrylonitrile styrene acrylate</span> Chemical compound

Acrylonitrile styrene acrylate (ASA), also called acrylic styrene acrylonitrile, is an amorphous thermoplastic developed as an alternative to acrylonitrile butadiene styrene (ABS), that has improved weather resistance. It is an acrylate rubber-modified styrene acrylonitrile copolymer. It is used for general prototyping in 3D printing, where its UV resistance and mechanical properties make it an excellent material for use in fused filament fabrication printers, particularly for outdoor applications. ABS is also widely used in the automotive industry.

References

  1. 1941–69: Changing Times. Orlon® : 1941 Archived July 9, 2015, at the Wayback Machine . Dupont Corporation
  2. Stauffer, Jeanne (2004). Sewing Smart with Fabric. DRG Wholesale. ISBN   9781592170180.
  3. Dedic, Bette Jo; Potter, Mike (February 1995). "Fabric Insect Pests: Clothes Moths & Carpet Beetles" (PDF). University of Kentucky: College of Agriculture, Food, and Environment. Retrieved January 6, 2016.
  4. Inside the lonely fight against the biggest environmental problem you've never heard of | Guardian Sustainable Business. The Guardian (2014-10-27). Retrieved on 2017-01-26.
  5. Williams, Alan. "Washing clothes releases thousands of microplastic particles into environment, study shows". Plymouth University. Retrieved October 9, 2016.
  6. Napper, I. E.; Thompson, R. C. (2016). "Release of Synthetic Microplastic Plastic Fibres From Domestic Washing Machines: Effects of Fabric Type and Washing Conditions". Marine Pollution Bulletin. 112 (1–2): 39–45. doi:10.1016/j.marpolbul.2016.09.025. hdl: 10026.1/8163 . PMID   27686821.
  7. Single clothes wash may release 700,000 microplastic fibres, study finds | Environment. The Guardian (2016-09-27). Retrieved on 2017-01-26.
  8. Browne, Mark Anthony (September 6, 2011). "Accumulation of Microplastic on Shorelines Worldwide: Sources and Sinks". Environmental Science and Technology. 45 (21): 9175–9179. Bibcode:2011EnST...45.9175B. doi:10.1021/es201811s. PMID   21894925. S2CID   19178027.