The Growth of the Man-Made Fiber Industry

Abstract

THE ORIGIN of the man-made fiber industry probably goes back to 1855 when the first known patent for the manufacture of rayon was issued in Europe to one George Audremars, a chemist. In his process cellulose was obtained from the bark of mulberry trees by nitration and then dissolved in a mixture of ether and alcohol. The resulting chemical compound was then combined with a rubber solution to form a mixture from which a crude type of filament was spun. There followed a number of other advancements in the science of producing fibers from cellulose and chemicals. In 1892, a viscose solution was developed from which the manufacture of a commercial filament was attempted. Finally in 1905, after years of further research, the first commercial production of rayon began, using what is known today as the viscose process. The second important method for making rayon employs the treatment of cellulose with acetic acid. In 1903, an English scientist by the name of G. W. Miles, discovered that cellulose acetate treated with acetone produced a solution that could then be forced through spinnerettes to form a filament fiber. But it was not until after World War I, following years of additional extensive research, that the first commercial production of rayon using the acetate process began in England. Both the viscose and the acetate processes usually employ cellulose obtained from either cotton linters or wood. Although rayon was suitable in many applications as a textile fiber, it had its limitations, such as a relatively low tensile strength, lack of elasticity, a tendency to wrinkle, and susceptibility to shrinkage. To overcome many of the deficiencies of rayon, a new group of man-made fibers, known as chemical or synthetic fibers, was discovered, beginning in 1938 with the first patent issued to the Du Pont Company for nylon. These fibers are produced from petroleum, natural gas, coal, air, salt, and water, and include in addition to nylon, the acrylics, polyesters, polyvinyls, polypropylenes, and spandex. Except for nylon, these newer synthetic fibers were not manufactured in any large volume until after 1950. The third major classification of man-made fibers, and perhaps the oldest in their origin and development, is that of the glass fibers. Glass in its molten stage is viscous in character, and when poured or stretched strings out tenuously and forms thread-like strands or fibers. Thus, quite unintentionally the first form of glass produced by man was a fiber. After the turn of the 19th century, efforts were made in Europe to produce glass fiber commercially in such items as lampshades and insulating materials requiring high heat resistance. But it was only in the late 1930's that a glass fiber of sufficient fineness was developed which was more suitable for a wider range of textile applications than the relatively coarse glass fiber produced until that time. Since glass fiber is exceptionally strong, resistant to chemicals and other corrosive substances, and nonflammable, it is advantageous in many textile applications that require these characteristics. In the world today the strong growth trend in the use of man-made fibers is best illustrated by reference to Table I.