POLYESTER

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POLYESTER

• History
• Forms
• Manufacturing Process
• Future

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Definition

• Polyester (aka Terylene) is a category of
  polymers which contain the ester functional group
  in their main chain.

Polyester is currently defined as

• Long chain polymers chemically composed of at
  least 85 by weight of an ester and a dihydric
  alcohol and terephthalic acid. The name
  polyester refers to the linkage of several
  monomers (esters) within the fiber.

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History

• In 1926, United States-based E.I. du Pont de
  Nemours and Co. began research into very large
  molecules and synthetic fibers
• W.H. Carothers, centered on what became nylon,
  the first synthetic fiber.
• 1939-41, British research chemists took interest
  in the du Pont studies and conducted their own
  research in the laboratories of Calico Printers
  Association, Ltd. This work resulted in the
  creation of the polyester fiber known in England
  as Terylene.
• In 1946, du Pont purchased the right to produce
  this polyester fiber in the United States.
• The company conducted some further developmental
  work, and in 1951, began to market the fiber
  under the name Dacron

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Raw Materials

• Coal
• Air
• Water
• Petroleum

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Forms Of Polyester

1. Filament
2. Staple
3. Tow
4. Fiberfill

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Uses Of Different Form In Different Places

1. In the filament form, each individual strand of
   polyester fiber is continuous in length,
   producing smooth-surfaced fabrics
2. In staple form, filaments are cut to short,
   predetermined lengths. In this form polyester is
   easier to blend with other fibers
3. Tow is a form in which continuous filaments are
   drawn loosely together
4. Fiberfill is the voluminous form used in the
   manufacture of quilts, pillows, and outerwear

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Microscopic View
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Different Structures Of Polyester
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STRUCTURE AND APPERANCE

• COLOURLESS AND TRANSPARENT
• SMOOTH AND LUSTURUOS
• SHAPE AS WE REQIURE
• SHINY GLASSROD LIKE

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Polyester Fiber Characteristics

• 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
• Retains heat-set pleats and crease
• Easily washed

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Polyester Blends

• Polyester and Cotton
• Resist wrinkles
• Resist stains
• Retain shape

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Polyester Blends

• Polyester and Wool
• Wrinkle resistance
• Shape retention
• Increase durability

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Polyester Blends

• Polyester and Rayon
• More durable
• Shape retention
• More resilience

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Manufacturing Filament Yarn

• Polymerization
• Drying
• Melt spinning
• Drawing the fiber
• Winding

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• Polymerization
• To form polyester, dimethyl terephthalate is
  first reacted with ethylene glycol in the
  presence of a catalyst at a temperature of
  302-410F (150-210C).
• The resulting chemical, a monomer (single,
  non-repeating molecule) alcohol, is combined with
  terephthalic acid and raised to a temperature of
  472F (280C). Newly-formed polyester, which is
  clear and molten, is extruded through a slot to
  form long ribbons.
• Drying
• After the polyester emerges from polymerization,
  the long molten ribbons are allowed to cool until
  they become brittle. The material is cut into
  tiny chips and completely dried to prevent
  irregularities in consistency.

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Melt spinning

• Polymer chips are melted at 500-518F (260-270C)
  to form a syrup-like solution. The solution is
  put in a metal container called a spinneret and
  forced through its tiny holes, which are usually
  round, but may be pentagonal or any other shape
  to produce special fibers. The number of holes in
  the spinneret determines the size of the yarn, as
  the emerging fibers are brought together to form
  a single strand.
• At the spinning stage, other chemicals may be
  added to the solution to make the resulting
  material flame retardant, antistatic, or easier
  to dye.

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• Drawing the fiber
• When polyester emerges from the spinneret, it is
  soft and easily elongated up to five times its
  original length. This increases the strength,
  tenacity, and resilience of the fiber. This time,
  when the filaments dry, the fibers become solid
  and strong instead of brittle.
• Drawn fibers may vary greatly in diameter and
  length, Also, as the fibers are drawn, they may
  be textured or twisted to create softer or duller
  fabrics.
• Winding
• After the polyester yarn is drawn, it is wound on
  large bobbins or flat-wound packages, ready to be
  woven into material.

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Physical Properties

• Specific weight 1.22-1.38 gm/cm
• Tenacity up to 85 cN/tex
• Moisture regain 0.2-0.5
• Heat Resist 150-200
  C
• Sunlight better
  resistance
• Insects no effect

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Chemical properties

• Acids At room temperature, PET is resistant to
  organic and moderate strength mineral acids. At
  high temperatures, PET strength loss in moderate
  strength acids can be appreciable. Strong acids
  such as concentrated sulfuric acid dissolve and
  depolymerize PET.
• Alkalies Polyester ?bers have good resistance to
  weakly alkaline chemicals and moderate resistance
  to stronglyalkaline chemicals at room
  temperature. PET ?bers are attacked by strongly
  alkaline substances.
• Organic Solvents PET ?bers are generally
  insoluble in organic solvents, including cleaning
  ?uids.

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Demand For Polyester
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RECYCLING
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FUTURE

• Biodegradable and biocompatible
  poly(3-hydroxybutyrate-co-3-hydroxyvalerate)
  (PHBV), a copolymer of microbial polyester, was
  fabricated as a Nano fibrous mat by electro
  spinning
• The researchers have developed a process in
  which polyester is dramatically strengthened with
  a material known as a liquid crystalline polymer.
  The liquid crystalline polymer used in the
  research is called Vectra , a plastic material
  similar to Kevlar that is five times stronger
  than steel. Polyester is used because its
  chemical structure is ideal for making bonds with
  the liquid crystalline polymer

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Some Major Polyester Fiber Uses

• Apparel Every form of clothing
• Home Furnishings Carpets, curtains, draperies,
  sheets and pillow cases, wall coverings, and
  upholstery
• Other Uses hoses, power belting, ropes and nets,
  thread, tire cord, auto upholstery, sails, floppy
  disk liners, and fiberfill for various products
  including pillows and furniture