ELASTOMERS

Tanvir Mahady Dip

Lecturer, BuTex
 ELASTOMERIC FIBERS
Elastomeric fibers are those that shows elasticity characteristics associated with natural rubber, they will stretch to
several times their original length and on release will snap back quickly to recover their original length almost
completely.

For a long time, natural rubber have been used in textile industry to provide stretch properties in fabrics and garments.
HISTORY

In 1920 fibrous rubber was first developed. Unfortunately, rubber has some short comings with respect to its use as a
textile material, chemists have been searching for a material which will be far superior in its recovery force over rubber.

In the early 1960 a new type of Elastomeric thread appeared based on Polyurethane. These synthetic threads now
known as spandex (Originally made by Du Pont), under F.T.C nomenclature. The first spandex fiber, Du Pont's Lycra
was introduced to market on 1958, commercial production began in 1960-61.

The generic name Spandex was adopted by U.S. Federal Trade Commission for fibers of segmented PU type, official
definition follows, “A manufactured fiber in which the fiber-forming substance is a long chain synthetic polymer
composed of at least 85% of segmented PU”.

"Spandex" is the preferred name in North America; elsewhere it is referred to as "elastane".

Other spandex tradenames

Lycra, Glospan, Vyrene, Blue C, Spanzelle etc.
 POLYURETHANE AND SEGMENTED POLYURETHANE
Polyurethanes are fibers made by reaction taking place between small molecules, in which linkage of molecules
occurs through formation of Urethane group ( - NHCOO —). Linear PU may be made by reaction of a glycol with di-
isocyanate.

For example: reaction of butane diol with toluene di-isocyanate results in formation of a PU in following way,
Segmented Polyurethanes is composed with a soft or flexible
segment (macroglycol) bonded together with a hard or rigid segment
(Di-isocyanate). During the development of PU polymers, segments
of molecules are deliberately tailored to perform their desired
functions.

Soft segment of considerable size overcomes the lack of flexibility

whereas Hard segment assures cohesion of interchain bonding

SPANDEX fibers are stronger than natural rubbers and has greater
recovery power. There are generally 2 types of PU fiber, 1) Polyether types & 2) Polyester types

TYPES The polymers formed by linking preformed segments of polyether or polyester molecules, via the
urethane group, may be essentially linear molecules, or they may be branched and/or cross-
linked into three dimensional structures. The linear types are generally capable of melting, and
will dissolve in appropriate solvents. The three-dimensional types may be completely insoluble
and non-melting.
CHEMISTRY
 MANUFACTURING
Spandex are spun from segmented PU following a series of chemical stages:

▪ Production of low molecular weight polymer (Pre-polymer)

▪ Reaction of pre-polymer with Di-isocyanate

▪ Coupling of isocyanate-terminated pre-polymer form segmented PU

Described below:

1. Production of low molecular weight polymer : This step is to create soft segment which provides amorphous region
that allows unfolding and permits extension. 2 classes of compounds (Polyester or Polyether) are used, material
produced being polymer of low molecular weight (500 to 4000) with reactive –OH terminal group. They are AKA
Macroglycol.

Polyester is made by condensation The soft segment structure

of Dicarboxylic Acid with Glycol influences below properties:
1 Polyether is made by ring opening
• Melting point
• Flexibility
• Chemical stability
of Cyclic Ethers
 MANUFACTURING
2.Reaction of Pre-polymer with Di-isocyanate:

The macro glycols previously manufactured are reacted with presence of Di-isocyanate. The terminal hydroxyl groups of
macro glycol reacting with isocyanate group to form urethane group.

The reactivity of Di-isocyanate depends on its structure. Generally

2
aromatic Di-isocyanate is used which is commercially available.

3.Coupling of Iso-cyanate terminated Pre-polymer to form segmented

Polyurethane:

The final step is to make hard segment of the Polyurethane by Chain

Extension or Coupling of iso-cyanate terminated pre-polymer by

3
reaction with low molecular weight bi-functional compounds like
glycol or diamine. The product is a polymer having hydrogen bonded
sites in the form of urethane.
MACROGLYCOL & DI-ISOCYANATE
Macroglycol:
1. Can be Polyester, Polyether, Polycarbonate, Polycaprolactone
or combination of these.
2. These are long chain polymers having Hydroxyl (-OH) groups
on both sides.
3. The important feature is they are long and flexible.
4. This part is responsible for stretch characteristics.

Di-isocyanate:
1. The Other polymer is a polymeric di-isocyanate.
2. This is a shorter chain polymer having iso-cyanate group
on both sides.
3. The important characteristics is rigidity which provides
strength.
 SPINNING
Spinning technique depends upon the type of polymer. The spandex segmented
Polyurethanes are essentially linear which are very much soluble in the solvents.
Other segmented polyurethanes may be branched or cross-linked which are
insoluble.

a) Linear Soluble Polyurethanes: Soluble Polyurethanes are dissolved in an

appropriate solvent (such as Di Methyl Formamide) and the solution may be
extruded through spinnerets into a coagulation bath (Wet Spinning) or into an
atmosphere which removes the solvent (Dry Spinning). The techniques are
essentially same as those used for spinning other Hard Fibers with due
allowance for spandex fibers.

b) Branched or Cross-linked Insoluble Polyurethanes: When molecule of PU is Fibers are produced as monofilaments
allowed to grow into a 3-dimensional structure, it is insoluble and cannot be with round cross section or as partly-fused
spun by above techniques. Branching occurs due to reaction of end multifilament. Monofilament can also be
isocyanate group with active hydrogen atoms in the molecular chain making
cross linking. So melt, dry and wet spinning cannot be applied. So a special
made by cutting thin sheets of polymer.
spinning process is employed where iso-cyanate terminated pre polymer is
spun at a stage when it forms a viscous dope. The jets emerging into an Spandex are generally clear and near
environment which carries chain extender which diffuses into fiber and transparent or white. Color may
reacts. The cross linking takes place in the final stage.
deteriorate with age.
 HEAT SETTING
Spandex is a thermoplastic fiber and may be heat set like any other Fibers. Heat setting is
imparted to ensure dimensional stability in fabric and garments.

Fabric requiring heat setting should be handled with following principle as basis:

1. Temperature should be kept as low as possible which will be effective with heat
setting.

2. Tension should be kept to a minimum, consistent with control of fabric dimension.

3. Exposure time should be balanced with temperature to avoid over setting with a
consequent decrease in power.

4. Heat setting should not be used to compensate for short comings of fabric
construction and manufacturing.
SET % of Elastomeric Fibers
Set percentage is a measure occurring due to elongation recovery
characteristic of filaments or fibers. When elastic recovery is not 100%, set
percentage can be measured as below: A B C D

Set % = BC/AB X 100% Fig: Effect of Heat Settings on

Fiber or filament with lower set % is always better. Polymer Bonds (In General)
 PROPERTIES
※ Physical Properties:

I. Tenacity: As polymer contains segmented structure, they show

stronger behavior than natural rubber. Breaking tenacity of spandex is
4.9-8.8 cN/Tex (0.55-1.0 g/Den), compared with 2.2 cN/Tex (0.25
g/Den) for natural rubber. Tensile properties are affected only slightly
by water.

II. Elongation: Breaking extension range from 400-700% depending with

denier.

III. Elastic Recovery: They have snap back rubber like elasticity, but
recovery is not as complete as natural rubber. In some cases, there is a
residual extension non recoverable after stretching (a degree of
permanent set). The set usually diminishes with time as fiber is subject
to relax. Increase in temperature speeds up recovery.

IV. Specific Gravity: 1.2 to 1.25

V. Effect of Moisture: Most Spandex fiber has regain of order 1.0 to 1.3%
 PROPERTIES
※ Chemical Properties: ※ Thermal Properties:

I. Acid: Most spandex has good resistance against cold Spandex are commonly thermoplastic. Sticking becomes
dilute acids but may be attacked under more severe noticeable in some cases ranging from 150o C to 280o C.
condition. Melting points are in the range 130o C to 290o C.
II. Alkali: Resistance to alkali is generally good.
※ Biological Properties:
III. General Chemicals: Good resistance to most common
chemicals, including cosmetic oils and lotions. I. Insects: Completely resistant.

IV. Bleach: Generally good resistance against weaker II. Micro-organism: Completely resistant.
bleaches. Discoloration may occur in presence of hypo
chlorite and sodium chlorite bleaches. SPANDEX OVER RUBBER
Compared to rubber spandex is both stronger and more durable.
V. Organic Solvent: Generally have good resistance They also posses 2/3 times more restraining power with one-
against common solvents including dry cleaning
third less weight. Unlike rubber, spandex is resistant to both
solvents.
sun light and salt water.
VI. Sunlight: Generally good resistance, discoloration
might occur in case of prolonged exposure.
 END USAGE
Spandex Filaments are used in 4 Forms:

1 . Bare Filament, 2 . Covered Yarn, 3 . Core-Spun Yarn 4 . Core-twisted Yarn

Foundation garment, swim ware, power nets, narrow
fabrics, braid, knitted fabric, under garments, sports
ware, uniform, skinny jeans, socks, support hose, surgical
hose, shorts etc.
LYCRA
Lycra is the trade name for Spandex fiber. Du Pont
marketed lycra as a brand worldwide.
 REFERENCE
• Handbook of textile fibers, Vol-II, Man made fibers by J. Gordon Cook
• Production of synthetic fibers by AA Vaidya
• Technology of textile processing, Vol-I, Textile fibers by Dr. V.A. Shenai
• Spandex or Elastane Fiber, Slide Share, Link:
https://www.slideshare.net/sheshir/welcome-32761244