Polyester

Polyester is a term often defined as “long-chain polymers chemically composed of

at least 85% by weight of an ester and a dihydric alcohol and a terephthalic acid”.
In other words, it means the linking of several esters within the fibers. Reaction
of alcohol with carboxylic acid results in the formation of esters. Polyester fibers,
the synthetic fibers, are long chain polymers derived from coal, air, water, and
petroleum. They are formed through chemical reaction between an acid and
alcohol. In this reaction, two or more molecules combine to make a large
molecule whose structure repeats throughout its length. These molecules are very
stable and strong. There are variations in the compositions and therefore in the
properties of polyester fibers.

Polyester can also be classified as saturated and unsaturated polyesters.

Saturated polyesters refer to that family of polyesters in which the polyester

backbones are saturated. They are thus not as reactive as unsaturated polyesters.
They consist of low molecular weight liquids used as plasticizers and as reactants
in forming urethane polymers, and linear, high molecular weight thermoplastics
such as polyethylene terephthalate.

Unsaturated polyesters refer to that family of polyesters in which the backbone

consists of alkyl thermosetting resins characterized by vinyl unsaturation. They
are mostly used in reinforced plastics. These are the most widely used and
economical family of resins.

Depending on the chemical structure polyester can be a thermoplastic or

thermoset; however the most common polyesters are thermoplastics.

Structure

Polyester is currently defined as: "Long-chain polymers chemically composed of

at least 85 percent by weight of an ester and a dihydric alcohol and a terephthalic
acid."

The name "polyester" refers to the linkage of several monomers (esters) within
the fiber. Esters are formed when alcohol reacts with a carboxylic acid:
There are, therefore, many possible variations of the generic polyester fiber. Two
that are currently produced commercially are polyethylene terephthalate (PET)
and poly-1,4, cyclohexylene dimethylene (PCDT). A third polyester fiber,
polyethylene oxybenzoate (PEB) was manufactured in Japan during the 1970s
and early 1980s under the trade name A-Tell®. Production of this fiber was
discontinued, however, because it did not offer enough performance advantages
to remain competitive in the textile market.

Polyester is a smooth fiber with an even diameter. The fiber diameter usually
ranges from 12-25 micrometers (10-15 denier). The undyed fiber is slightly off-
white and partially transparent. The fibers are approximately 35% crystaline and
65% amorphous.

Close up of a polyester fiber

MANFACTURE

Most polyester is made from petroleum from which the constituent acids and
alcohols are derived. The types of processes that manufacturers use vary, and
little is known about specific manufacturing processes, because the companies
want to keep them a secret in order to remain competitive. Here is a general
description of how polyester is synthesized:

Polymerization
Condensation polymerization occurs when the acid and alcohol are reacted in a
vacuum at high temperatures. The polymerized material is extruded in the form
of a ribbon onto a casting trough or cooling wheel. After the ribbon hardens, it is
cut into chips.
Spinning
The chips are dried and then put into hopper reservoirs for melting. Polyester is a
"melt spun" fiber, which means that it is heated, extruded through the spinnerets,
and cools upon hitting the air. From there it is loosely wound around cylinders.

Drawing
The fibers are then hot stretched until they are about five times their original
length in order to decrease their width. The fiber is then wound onto cones as
filaments or is crimped and then is cut into staple lengths.

Types of Polyester
The polyester fibers are generally available in two varieties- PET (polyethylene
terephthalate) and PCDT (poly-1, 4-cyclohexylene-dimethylene terephthalate).
PET is the most common production. It is stronger than PCDT, while PCDT has
more elasticity and resilience. PET can be used alone or blended with other
fabrics for making wrinkle free and stain resistant clothing that can retain its
shape. PCDT is more suitable for heavier applications, such as draperies and
furniture coverings. Modifications can be introduced in each of these varieties for
obtaining specific properties.

PET Polyester
For manufacturing PET Polyester, the main raw material is
ethylene derived from petroleum. It is oxidized to produce a
glycol monomer dihydric alcohol which is further combined with
another monomer, terephthalic acid at a high temperature in a
vacuum. Polymerization, the chemical process that produces the
finished polyester, is done with the help of catalysts. The colorless
molten polyester then flows from a slot in a vessel on to a casting
wheel and takes shape of a ribbon as it cools to hardness. The polymer thus
produced is then cut into very small chips, dried to remove all moisture and
blended to make it uniform for getting it ready for spinning into yarn.
PCDT Polyester
This variation of polyester is made by condensing terephthalic acid with 1,4-
cyclohexane-dimethanol to form poly-1, 4-cyclohexylene-dimethylene
terephthalate
or the PCDT Polyester. As for PET Polyester, PCDT is processed for melt
spinning.

Composition Number of Examples of

Examples of
of the main repeating manufacturing
polyesters
chain units methods
Polyglycolide or
Polycondensation of
Aliphatic Homopolymer Polyglycolic acid
glycolic acid
(PGA)
Polylactic acid (PLA)
Ring-opening
Polycaprolactone
polymerization of
(PCL)
caprolactone
Polyethylene adipate
Copolymer
(PEA)
Polyhydroxyalkanoate
(PHA)
Polycondensation of
Polyethylene
Semi-aromatic Copolymer terephthalic acid
terephtalate (PET)
with ethylene glycol
Polycondensation of
Polybutylene
terephthalic acid
terephthalate (PBT)
with 2,3-butanediol
Polycondensation of
Polytrimethylene
terephthalic acid
terephthalate (PTT)
with 1,3-propanediol
Polycondensation of
ethylene glycol with
Polyethylene
one or more
naphthalate (PEN)
naphthalene
dicarboxylic acids
Aromatic Copolymer Vectran
Industry
Basics

Polyester is a synthetic polymer made of purified terephthalic acid (PTA) or its

dimethyl ester dimethyl terephthalate (DMT) and monoethylene glycol (MEG).
With 18% market share of all plastic materials produced, it ranges third after
polyethylene (33.5%) and polypropylene (19.5%).

The main raw materials are described as follows:

• Purified Terephthalic Acid – PTA

Synonym: 1,4 Benzenedicarboxylic acid,

Sum formula; C6H4 (COOH)2 , mol weight: 166,13

• Dimethylterephthalate – DMT

Synonym: 1,4 Benzenedicarboxylic acid dimethyl ester

Sum formula C6H4 (COOCH3)2 , mol weight: 194,19

• Mono Ethylene Glycol – MEG

Synonym: 1,2 Ethanediol

Sum formula: C2H6O2 , mol weight: 62,07

• Antimony trioxide – ATO

Synonym: none,

Mol weight: 291,51

Sum formula: Sb2O3

• Polyethylene Terephthalate

Synonym / abbreviations: polyester, PET, PES

Sum Formula: H-[C10H8O4]-n=60-120 OH,

mol unit weight: 192,17

There are several reasons for the importance of Polyester:

• The relatively easy accessible raw materials PTA or DMT and MEG
• The very well understood and described simple chemical process of
polyester synthesis
• The low toxicity level of all raw materials and side products during
polyester production and processing
• The possibility to produce PET in a closed loop at low emissions to the
environment
• The outstanding mechanical and chemical properties of polyester
• The recyclability

Characteristics of polyester

• Polyester fabrics and fibers are extremely strong.

• Polyester is very durable: resistant to most chemicals, stretching and
shrinking, wrinkle resistant, mildew and abrasion resistant.
• Polyester is hydrophobic in nature and quick drying. It can be used for
insulation by manufacturing hollow fibers.
• Polyester retains its shape and hence is good for making outdoor clothing
for harsh climates.
• It is easily washed and dried.

Uses
Fabrics woven from polyester thread or yarn are used extensively in apparel and
home furnishings, from shirts and pants to jackets and hats, bed sheets, blankets
and upholstered furniture. Industrial polyester fibers, yarns and ropes are used in
tyre reinforcements, fabrics for conveyor belts, safety belts, coated fabrics and
plastic reinforcements with high-energy absorption. Polyester fiber is used as
cushioning and insulating material in pillows, comforters and upholstery
padding.
Polyesters are also used to make "plastic" bottles, films, tarpaulin, canoes, liquid
crystal displays, holograms, filters, dielectric film for capacitors, film insulation
for wire and insulating tapes.