Nylon’s story began in the 1930s at the DuPont company’s research lab. A team led by chemist Wallace Carothers was exploring the potential of polymers and looking for a material that could be a substitute for silk and could be commercially viable.
After years of research, Carothers and his team discovered a polymer that could be drawn into a fiber with a silk-like appearance. This polymer was strong, elastic, and durable. The new fiber was initially named “fiber 66,” referring to the six carbon atoms in the adipic acid and hexamethylene diamine monomers used to produce the polymer chain.
The debut of nylon fabric
DuPont introduced nylon to the market on October 27, 1938. The company decided to present the new fiber at the 1939 New York World’s Fair, showcasing it as the material of the future. The first commercial product to use nylon was a toothbrush with nylon bristles, which went on sale in 1938.
However, it was the introduction of women’s stockings made from nylon that truly captured the public’s imagination. These stockings were an instant hit because they were more durable than silk stockings and had a desirable sheer look. They went on sale on May 15, 1940, and were sold out within hours. This day was later referred to as “Nylon Day.”
Impact of World War II
During World War II, the production of nylon was redirected towards the war effort. Nylon’s durability and strength made it an excellent material for parachutes, ropes, and aircraft tires, replacing silk and hemp which were previously used.
After the war, the demand for nylon stockings surged once again, leading to what was known as the “nylon riots” as consumers clamored for the scarce material.
Post-war expansion and innovation
With the end of the war, DuPont resumed the production of nylon for consumer goods, and the material’s use rapidly expanded. Nylon began to be used in a variety of clothing items, home furnishings, and industrial applications. The versatility of the fabric led to innovations in textiles, such as its use in blends with other fibers.
Production of nylon fabric
The raw materials
Nylon is a synthetic polymer, which means it is a plastic, and like all plastics, it is made from petrochemicals. The primary raw material for making nylon is crude oil. The oil is refined and processed into specific chemicals, notably adipic acid and hexamethylene diamine. These are the monomers that are used to create the polymer known as nylon.
Creating the polymer
The production of nylon polymer begins with a reaction known as polymerization. The adipic acid and hexamethylene diamine are combined in a reaction vessel with water. When these compounds react, they bond together, forming a long chain or polymer, releasing water in the process. This reaction is carefully controlled to ensure that the molecular weight and degree of polymerization are correct, which will determine the properties of the nylon.
Melting and extrusion
Once the nylon polymer is created, it is melted and forced through a spinneret, which is a metal disc with tiny holes that functions like a sieve. As the molten nylon is pushed through the holes of the spinneret, it forms long, thin strands of fiber. This process is known as extrusion. The size and shape of the holes in the spinneret determine the diameter and cross-section of the fibers.
Drawing and cooling
After extrusion, the nylon fibers are still not ready for textile production. They are drawn, which means they are stretched to align the polymer molecules, improving the fiber’s strength and elasticity. The fibers are then cooled, solidifying them into their final form. This can be done through various methods, including air-cooling or passing the fibers through a water bath.
Texturizing
Nylon fibers can be texturized to give them certain properties, such as a softer feel or increased elasticity. This is done by crimping the fibers, which involves twisting and heat-setting them to create a bulkier yarn with more texture.
Spinning into yarn
The individual nylon fibers are then spun into yarn. Multiple fibers are twisted together to create a single strand of yarn. This yarn can then be woven or knitted to create a fabric. The type of weave or knit used will affect the texture, appearance, and properties of the final nylon fabric.
Dyeing and finishing
Nylon fabric can be dyed in a vast array of colors. The dyeing process typically occurs after the fabric has been woven or knitted. Nylon is known to be a good fabric for dyeing, with excellent colorfastness. After dyeing, the fabric can undergo various finishing processes, including softening, stain-proofing, or adding water resistance.
Quality control
Throughout the production process, quality control is essential. The nylon is tested for its strength, elasticity, and other properties to ensure it meets the required standards for its intended use.
The production of nylon fabric is a complex chemical process that transforms petroleum-based raw materials into fibers that are then spun into yarn and woven into fabric. The technology has evolved since its invention, making it more efficient and sustainable. Nylon remains a vital material in our daily lives, from clothing to car parts, and its production is a testament to human ingenuity in material science.
5 Uses of nylon fabric
- Apparel
Nylon is widely used in the fashion industry. Due to its strength and elasticity, it is an ideal material for items that require a degree of stretch and recovery, such as hosiery, lingerie, swimwear, activewear, and other form-fitting clothes. It’s also used in outerwear because of its wind and water resistance.
- Home furnishings
Nylon’s durability and resistance to abrasion make it a popular choice for home furnishings. It is often used in carpets, upholstery, and curtains, where its ability to retain color and resist wear and tear is particularly valued.
- Industrial applications
In the industrial sector, nylon’s toughness and resistance to chemicals and abrasion make it suitable for use in conveyor belts, hoses, ropes, and threads. It’s also used in airbags, seat belts, and other safety equipment in vehicles due to its high tensile strength.
- Outdoor gear
Nylon’s water-resistant and quick-drying properties make it an excellent material for outdoor gear. Tents, backpacks, and other camping equipment are often made from nylon. It is also used in making fishing nets, life vests, and parachutes.
- Technical uses
Nylon is utilized in advanced technical fields like the automotive and aerospace industries. It’s employed in the production of composite materials used in cars and aircraft due to its heat resistance and durability.
8 Benefits of nylon fabric
- Durability
Nylon is one of the most durable man-made fibers available. It has high tensile strength, which means it can withstand a significant amount of pulling force, making it resistant to tearing and ripping.
- Elasticity
Nylon fibers can stretch up to 33% of their length and still return to their original form. This elasticity is a key property for garments like hosiery and swimwear, which need to maintain their shape after stretching.
- Resilience
Nylon fabric can return to its original condition after being stretched or compressed, which means it resists wrinkles and holds its shape well. This resilience makes it a preferred material for travel clothing and sportswear.
- Lightweight
Nylon is a lightweight fiber, contributing to its comfort as apparel and usefulness in applications where reducing weight is critical, such as in outdoor gear and technical applications.
- Quick drying
Nylon fabric dries quickly because it absorbs very little moisture. This quick-drying ability is particularly beneficial for outdoor clothing and gear, where being able to dry out quickly can be crucial.
- Mildew resistance
The fabric resists mildew, mold, and fungi since it doesn’t retain moisture. This is particularly important for outdoor gear that may be exposed to damp conditions.
- Versatility
Nylon can be blended with other fibers to create fabrics that combine the best properties of each material. For example, blending nylon with cotton can improve strength and durability while maintaining comfort.
- Easy care
Nylon fabric is machine washable and dries quickly. It also maintains its color well, resisting fading even after prolonged exposure to sunlight.
These uses and benefits highlight nylon’s versatility as a material. Its properties have made it indispensable in a wide variety of fields, and ongoing developments continue to expand its applications even further. The advantages of nylon make it a material that not only serves practical needs but also contributes to safety and technological innovation.
Conclusion
Nylon’s impact on the world has been significant. Its development not only changed how we dress but also how we approach material science and engineering challenges. As we continue to innovate, nylon serves as a reminder of how creativity and science can come together to create materials that shape our daily lives. Reach out to us, if you are looking for a reliable woven fabric manufacturer.
