Manufacturing Process, Properties,
and End Uses of Natural and Manmade Fibers
Introduction:
Fibers
play a crucial role in the textile industry, providing the raw material for
various fabrics and products. They can be categorized into natural fibers,
which are derived from plants and animals, and manmade fibers, which are
synthesized from various raw materials.
Natural
Fibers:
1.
Cotton Fiber:
Manufacturing Process:
Cotton fibers are harvested from the cotton plant's bolls. After harvesting,
the cotton undergoes ginning, which separates the fibers from seeds and other
impurities. The cleaned fibers are then carded and spun into yarn.
Properties: Cotton fibers are known for
their softness, breathability, and moisture absorbing properties. They are
comfortable to wear and suitable for warm weather.
End Uses: Cotton is widely
used for making clothing, bed linens, towels, and various textile products.
2.
Wool Fiber:
Manufacturing Process: Wool is obtained
from sheep, goats, or other animals with fleece. The fleece is sheared, and
then the wool undergoes processes like cleaning, carding, and spinning.
Properties: Wool is known for its
warmth, moisture wicking properties, and natural insulation. It is resilient,
elastic, and comfortable to wear.
End Uses: Wool is used to make a variety of clothing items, blankets, carpets, and upholstery.
2.
Manmade Fibers:
1.
Polyester Fiber:
Manufacturing Process: Polyester is
produced through a polymerization process, where petrochemicals are converted
into polymer chips. These chips are then melted and extruded into filaments,
which are stretched and cooled to form fibers.
Properties: Polyester fibers are
durable, wrinkle resistant, and have good moisture wicking properties. They are
often blended with other fibers for various applications.
End Uses: Polyester is used in clothing,
sportswear, upholstery, and as a filling material in pillows and duvets.
2.
Nylon Fiber:
Manufacturing Process: Nylon is
synthesized from petrochemicals through a process called polymerization. The
resulting polymer is extruded into filaments, which are stretched and heat set
to form fibers.
Properties: Nylon fibers are strong,
resilient, and have excellent abrasion resistance. They also have good
elasticity and are used in applications requiring durability.
End Uses: Nylon is used in
hosiery, sportswear, swimwear, and various industrial applications like
automotive components.
3.
Rayon Fiber:
Manufacturing Process: Rayon is a
semisynthetic fiber derived from wood pulp or cellulose. The cellulose is
dissolved in chemicals to create a viscous solution, which is then extruded
through spinnerets to form fibers.
Properties:
Rayon has a soft, silky feel, and it drapes well. It can mimic the properties
of natural fibers like cotton, silk, or wool, depending on the manufacturing
process.
End Uses: Rayon is used in
clothing, upholstery, and as a component in various blends.
Different Methods of Fabric
Construction Woven, Knitted, and
Nonwoven Fabrics
1.
Woven Fabrics:
Method
of Construction:
Definition: Woven fabrics are created
by interlacing two sets of yarns, the warp (lengthwise) and weft (crosswise),
at right angles.
Process: The warp yarns are stretched
on a loom, and the weft yarn is passed through them in a systematic pattern.
Types of Weaves:
Common weaves include plain weave, twill weave, and satin weave.
Characteristics:
Woven fabrics tend to be stable, have a structured appearance, and are less
stretchy compared to knitted fabrics.
Properties:
Strength: Woven
fabrics are generally stronger due to the crisscross pattern of yarns.
Durability:
They are durable and less likely to stretch out of shape.
Stiffness: Can
be stiff or rigid depending on the weave.
Breathability:
Breathability varies with weave type, but it's generally moderate.
End
Uses:
Clothing:
Common in formal attire, denim, suits, and dress shirts.
Home Textiles:
Used in upholstery, curtains, and bed linens.
Industrial
Applications: For heavy duty purposes like canvas for tents and bags.
2.
Knitted Fabrics:
Method
of Construction:
Definition: Knitted fabrics
are made by interlocking loops of yarn in a continuous row.
Process: Knitting machines
create these loops using one or more needles.
Types of Knits:
Common knit types include single jersey, rib knit, and interlock knit.
Characteristics:
Knitted fabrics are flexible, stretchy, and comfortable.
Properties:
Stretch:
Knitted fabrics have excellent stretch and recovery properties.
Comfort: They
are comfortable to wear and conform to the body's shape.
Breathability:
Highly breathable due to the open structure between loops.
Drapability:
They often have good drape due to their flexibility.
End
Uses:
Apparel: T-shirts,
socks, sweaters, and sportswear.
Active wear:
Due to their stretch and moisture wicking properties.
Undergarments:
Comfortable undergarments and lingerie.
Home Textiles:
Some lightweight knits are used in bed linens and towels.
3.
Nonwoven Fabrics:
Method
of Construction:
Definition: Nonwoven fabrics
are produced by bonding or felting fibers together, rather than weaving or
knitting.
Process: Fibers can be bonded using
heat, chemicals, or mechanical methods.
Types: Nonwovens can range from loosely
felted to tightly bonded materials.
Characteristics:
They are often lightweight and can be made to be either strong or disposable.
Properties:
Strength:
Varies widely depending on the manufacturing process.
Disposable:
Some nonwovens are designed to be single use or disposable.
Absorbency: Can
be engineered to have high or low absorbency.
Barrier Properties:
Used for filtration, insulation, or as a barrier against liquids.
End
Uses:
Hygiene
Products: Diapers, sanitary napkins, and wet wipes.
Medical
Textiles: Surgical gowns, masks, and wound dressings.
Packaging: Used
in packaging materials and bags.
Geotextiles:
For soil stabilization, erosion control, and drainage.
Textiles Finishes: Classification,
Processing, and Purposes
Introduction to Textiles Finishes
Textile
finishes are essential processes applied to fabrics to enhance their
appearance, performance, and functionality. These finishes can be categorized
based on their classification, processing methods, and their specific purposes.
Classification of Textiles Finishes
Textiles
finishes can be classified into various categories based on their nature and
functions:
1.
Mechanical Finishes
Mechanical
finishes involve altering the fabric's physical properties through mechanical
processes. Common mechanical finishes include:
Calendaring:
This process involves passing fabric through heated rollers, which smoothens
the surface, enhances lustre, and reduces thickness.
Embossing: Textile surfaces can be
embossed to create patterns or designs. This is often used for decorative
purposes.
Pleating: Pleats are
formed in the fabric by applying heat and pressure. This finish adds texture
and style to the fabric.
2.
Chemical Finishes
Chemical
finishes modify the fabric's properties through chemical treatments. These can
be further subdivided into several categories:
Water
Repellent and Water Resistant Finishes: These finishes make
fabrics resistant to water penetration, making them suitable for raincoats,
outdoor gear, and upholstery.
Flame
Retardant Finishes: Fabrics treated with flame retardant
chemicals are less likely to catch fire, making them ideal for applications
like firefighter uniforms.
Antimicrobial
Finishes: These finishes inhibit the growth of microorganisms,
ensuring fabrics remain hygienic. They are commonly used in healthcare textiles
and sportswear.
3.
Heat Finishes
Heat
finishes involve the application of heat to alter the fabric's properties.
Common heat finishes include:
Heat
Setting: This process involves subjecting fabrics to
controlled heat to stabilize their dimensions and reduce shrinkage.
Heat
Transfer Printing: Heat is used to transfer a design from a
printed paper to the fabric. This is commonly used in textile printing.
4. Coating Finishes
Coating
finishes add a layer of a different material to the fabric's surface. Types of
coating finishes include:
Polyurethane
Coating: Applied to create waterproof and breathable fabrics,
commonly used in outdoor clothing.
PVC Coating: Creates a waterproof
barrier and is used in rainwear and inflatable structures.
Processing of Textiles Finishes
The application of textile finishes involves various
processing methods:
1.
Padding
Padding
involves passing the fabric through a bath of finish solution and then
squeezing it between rollers to remove excess liquid. This is common for
applying chemical finishes.
2. Exhaustion
In this
method, fabrics are immersed in a finish bath until they have absorbed the
desired amount of finish. The excess liquid is then drained off.
3. Spraying
Finishes
can be applied by spraying a fine mist of finish solution onto the fabric's
surface. This method is often used for water repellent finishes.
4. Printing
Printing
methods are used to apply finishes with precision and create decorative
patterns. Heat transfer printing is an example.
Purposes of Textiles Finishes
Textile finishes serve a multitude of purposes:
Aesthetic
Enhancement: Finishes can improve the fabric's
appearance by adding sheen, texture, or patterns.
Functional Enhancement: Many finishes
enhance fabric performance, such as making it water repellent, fire resistant,
or antimicrobial.
Comfort: Finishes can improve the
comfort of textiles by regulating moisture, temperature, and softness.
Durability: Some finishes
improve the fabric's durability and resistance to wear and tear.
Environmental Impact: Eco friendly finishes
can reduce the environmental impact of textiles, making them more sustainable.
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