Spandex fibers

Polyurethanes. About 3% of the U.S. polyurethanes market in 1988 was derived from the condensation product of polyisocyanates with low molecular weight polyadipates having hydroxyl end groups (195). In 1986 this amounted to 29,000 t, or 4% of total adipic acid consumption. The percentage was similar in Western Europe. About 90% of these adipic acid containing polyurethanes are used in flexible or semirigid foams and elastomers, with the remainder used in adhesives, coatings, and spandex fibers. 

The physical characteristics of current commercial mbber and spandex fibers are summarized ia Table 1. Typical stress—straia curves for elastomeric fibers, hard fibers, and hard fibers with mechanical stretch properties ate compared ia Eigute 1. 

Fig. 1. Stress—strain curves A, hard fiber, eg, nylon B, biconstituent nylon—spandex fiber C, mechanical stretch nylon D, spandex fiber E, extruded latex...

Both spandex fibers and mbber threads normally contain antioxidants and other stabilizers. 

To produce a spandex fiber by reaction spinning, a 1000—3500 molecular weight polyester or polyether glycol reacts with a diisocyanate at a molar ratio of about 1 2. The viscosity of this isocyanate-terrninated prepolymer may be adjusted by adding small amounts of an inert solvent, and then extmded into a coagulating bath that contains a diamine so that filament and polymer formation occur simultaneously. Reactions are completed as the filaments are cured and solvent evaporated on a belt dryer. After appHcation of a finish, the fibers are wound on tubes or bobbins and rewound if necessary to reduce interfiber cohesion. 

Dry Spinning. On a worldwide basis, about 90% of all spandex fibers are produced by various adaptations of dry spinning (15,16). The solution dry spinning process is illustrated in Figure 5. The polymer spinning solution is metered at a constant temperature by a precision gear pump... 

Solvent Resistance. Elastomeric fibers tend to swell in certain organic solvents mbber fibers swell in hydrocarbon solvents such as hexane. Spandex fibers become highly swollen in chlorinated solvents such as tetrachloroethylene [127-18-4] (Perclene). Although the physical properties of spandex fibers return to normal after the solvent evaporates, considerable amounts of its stabilizers may have been extracted. Therefore, the development of stabilizers that are more resistant to solvent extraction has become important as solvent scouring during mill processing replaces aqueous scouring at many mills, especially in Europe (26). 

A worldwide Hst of spandex fiber and related elastomer producers is shown in Table 2. Most process developments have occurred in the United States, Germany, Japan, and Korea. A large proportion of worldwide capacity is controlled by Du Pont, either directly or through subsidiaries and joint ventures. These include three plants in North America, two in South America, two in Europe, and two in Asia. 

Commercially, elastomeric fibers are almost always used in combination with hard fibers such as nylon, polyester, or cotton. Use levels vary from a low of about 3% in some filling stretch cotton fabrics to a high of about 40% in some warp-knit tricot fabrics. Raschel fabrics used in foundation garments normally contain 10—20% spandex fiber. 

Prices of spandex fibers are highly dependent on thread size selling price generally increases as fiber tex decreases. Factors that contribute to the relatively high cost of spandex fibers include (/) the relatively high cost of raw materials, (2) the small size of the spandex market compared to that of hard fibers which limits scale and thus efficiency of production units, and (J) the technical problems associated with stretch fibers that limit productivity rates and conversion efficiencies. 

Gut Rubber and Extruded Latex. The manufacturing technology for cut and extmded mbber thread is much older and more widely known than that for spandex fibers. Because production faciUties can be installed with relatively modest capital investment, manufacture of mbber thread is fragmented and more widely distributed with a few major and many minor producers. On a worldwide basis, Fikattice of Italy is the largest mbber thread producer with modem extmded latex plants in Italy, Spain, Malaysia, and the United States. Second in production capacity is the Globe Manufacturing Co., Fall River, Massachusettes with production operations in the United States and the UK. These firms also produce spandex fibers. 

Spandex Fibers. Spandex fibers are suppHed for processing into fabrics in four basic forms as outlined in Table 3. Bare yams are suppHed by the manufacturer on tubes or beams and can be processed on conventional textile equipment with the aid of special feed and tension devices. In covered yams, the spandex fibers are covered with one or two layers of an inelastic filament or staple yam the hard yam provides strength and rigidity at full extension, which faciUtates knitting and weaving. 

Spandex fibers are available as fine as 1.1 tex (10 den), and the finest extmded latex thread available is about 16 tex (140 den). The availabihty of spandex fibers in such fine sizes and their unique properties compared to mbber, eg, dyeabiUty, high modulus, abrasion resistance, and whiteness, has allowed extensive penetration into hosiery and sportswear markets. 

Formaldehyde. Worldwide, the largest amount of formaldehyde (qv) is consumed in the production of urea—formaldehyde resins, the primary end use of which is found in building products such as plywood and particle board (see Amino resins and plastics). The demand for these resins, and consequently methanol, is greatly influenced by housing demand. In the United States, the greatest market share for formaldehyde is again in the constmction industry. However, a fast-growing market for formaldehyde can be found in the production of acetylenic chemicals, which is driven by the demand for 1,4-butanediol and its subsequent downstream product, spandex fibers (see Fibers, elastomeric). 

The late 1950s saw the emergence of cast elastomers, which led to the development of reaction injection mol ding (RIM) at Bayer AG in Leverkusen, Germany, in 1964 (see Plastics processing). Also, thermoplastic polyurethane elastomers (TPUs) and Spandex fibers (see Fibers, elastomeric) were introduced during this time. In addition, urethane-based synthetic leather (see Leather-LIKEmaterials) was introduced by Du Pont under the trade name Corfam in 1963. 

Polymeric isocyanates or PMDI ate cmde products that vary in exact composition. The main constituents are 40—60% 4,4 -MDI the remainder is the other isomers of MDI, trimeric species, and higher molecular weight oligomers. Important product variables are functionaHty and acidity. Rigid polyurethane foams are mainly manufactured from PMDI. The so-called pure MDI is a low melting soHd that is used for high performance polyurethane elastomers and spandex fibers. Liquid MDI products are used in RIM polyurethane elastomers. 

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