Rayon is a manufactured regenerated cellulose fiber. It is made from purified cellulose, primarily from wood pulp, which is chemically converted into a soluble compound. It is then dissolved and forced through a spinneret to produce filaments which are chemically solidified, resulting in synthetic fibers of nearly pure cellulose. Because rayon is manufactured from naturally occurring polymers, it is considered a semi-synthetic fiber. Specific types of rayon include viscose, modal and lyocell, each of which differs in manufacturing process and properties of the finished product.
- 1 History
- 2 Major fiber properties
- 3 Gallery of textures
- 4 Physical structure
- 5 Production method
- 6 Disposal and biodegradability
- 7 Alternative to cotton
- 8 Controversies
- 9 Producers
- 10 See also
- 11 References
- 12 Further reading
- 13 External links
The fact that nitrocellulose is soluble in organic solvents such as ether and acetone made it possible for Georges Audemars to develop the first "artificial silk" in about 1855, but his method was impractical for commercial use. Commercial production started in 1891, but the result was flammable and more expensive than acetate or cuprammonium rayon. Because of this, production was stopped before World War I. It was briefly known as "mother-in-law silk." Frank Hastings Griffin invented the double-godet, a special stretch-spinning process that changed artificial silk to rayon, rendering it usable in many industrial products such as tire cords and clothing. Nathan Rosenstein invented the spunize process by which he turned rayon from a hard fiber to a fabric. This allowed rayon to become a popular raw material in textiles.
Paul Schützenberger discovered that cellulose could be reacted with acetic anhydride to form cellulose acetate. The triacetate is only soluble in chloroform making the method expensive. The discovery that hydrolyzed cellulose acetate is soluble in more polar solvents, like acetone, made production of cellulose acetate fibers cheap and efficient.
The Swiss chemist Matthias Eduard Schweizer (1818–1860) discovered that tetraaminecopper dihydroxide could dissolve cellulose. Max Fremery and Johann Urban developed a method to produce carbon fibers for use in light bulbs in 1897. Production of cuprammonium rayon for textiles started in 1899 in the Vereinigte Glanzstoff Fabriken AG in Oberbruch. Improvement by the J. P. Bemberg AG in 1904 made the artificial silk a product comparable to real silk.
Finally, in 1894, English chemist Charles Frederick Cross, and his collaborators Edward John Bevan, and Clayton Beadle patented their artificial silk, which they named "viscose", because the reaction product of carbon disulfide and cellulose in basic conditions gave a highly viscous solution of xanthate. The first commercial viscose rayon was produced by the U.K. company Courtaulds Fibres in 1905. Courtaulds formed an American division, American Viscose, (later known as Avtex Fibers) to produce their formulation in the United States in 1910. The name "rayon" was adopted in 1924, with "viscose" being used for the viscous organic liquid used to make both rayon and cellophane. In Europe, though, the fabric itself became known as "viscose," which has been ruled an acceptable alternative term for rayon by the U.S. Federal Trade Commission.
The method is able to use wood (cellulose and lignin) as a source of cellulose while the other methods need lignin-free cellulose as starting material. This makes it cheaper and therefore it was used on a larger scale than the other methods. Contamination of the waste water by carbon disulfide, lignin and the xanthates made this process detrimental to the environment. Rayon was only produced as a filament fiber until the 1930s when it was discovered that broken waste rayon could be used in staple fiber.
The physical properties of rayon were unchanged until the development of high-tenacity rayon in the 1940s. Further research and development led to the creation of high-wet-modulus rayon (HWM rayon) in the 1950s. Research in the UK was centred on the government-funded British Rayon Research Association.
Major fiber properties
Rayon is a versatile fiber and is widely claimed to have the same comfort properties as natural fibers, although the drape and slipperiness of rayon textiles are often more like nylon. It can imitate the feel and texture of silk, wool, cotton and linen. The fibers are easily dyed in a wide range of colors. Rayon fabrics are soft, smooth, cool, comfortable, and highly absorbent, but they do not insulate body heat, making them ideal for use in hot and humid climates, although also making their handfeel cool and sometimes almost slimy to the touch.
The durability and appearance retention of regular viscose rayon are low, especially when wet; also, rayon has the lowest elastic recovery of any fiber. However, HWM rayon (high-wet-modulus rayon) is much stronger and exhibits higher durability and appearance retention. Recommended care for regular viscose rayon is dry-cleaning only. HWM rayon can be machine washed.
Industrial applications of rayon emerged around 1935. Substituting cotton fiber in tires and belts, industrial types of rayon developed a totally different set of properties, amongst which tensile strength (elasticity) was paramount. Outperforming polyester, industrial yarns are still produced for high performance tires (e.g. Cordenka, Germany).
Gallery of textures
- Rayon closeup 1.jpg
A sample of rayon from a skirt, photographed with a macro lens.
- Rayon closeup 2.jpg
Another skirt with a different texture.
- Rayon closeup 3.jpg
A blouse with a texture similar to the second.
Regular rayon has lengthwise lines called striations and its cross-section is an indented circular shape. The cross-sections of HWM and cupra rayon are rounder. Filament rayon yarns vary from 80 to 980 filaments per yarn and vary in size from 40 to 5000 denier. Staple fibers range from 1.5 to 15 denier and are mechanically or chemically crimped. Rayon fibers are naturally very bright, but the addition of delustering pigments cuts down on this natural brightness.
Regular rayon (or viscose) is the most widely produced form of rayon. This method of rayon production has been utilized since the early 1900s and it has the ability to produce either filament or staple fibers. The process is as follows:
- Cellulose: Production begins with processed cellulose(obtained from wood pulp and plant fibers).
- Immersion: The cellulose is dissolved in caustic soda: (C6H10O5)n + nNaOH → (C6H9O4ONa)n + nH2O
- Pressing: The solution is then pressed between rollers to remove excess liquid
- White Crumb: The pressed sheets are crumbled or shredded to produce what is known as "white crumb"
- Aging: The "white crumb" is aged through exposure to oxygen
- Xanthation: The aged "white crumb" is mixed with carbon disulfide in a process known as Xanthation, the aged alkali cellulose crumbs are placed in vats and are allowed to react with carbon disulfide under controlled temperature (20 to 30 °C) to form cellulose xanthate: (C6H9O4ONa)n + nCS2 → (C6H9O4O-SC-SNa)n
- Yellow Crumb: Xanthation changes the chemical makeup of the cellulose mixture and the resulting product is now called "yellow crumb"
- Viscose: The "yellow crumb" is dissolved in a caustic solution to form viscose
- Ripening: The viscose is set to stand for a period of time, allowing it to ripen: (C6H9O4O-SC-SNa)n + nH2O → (C6H10O5)n + nCS2 + nNaOH
- Filtering: After ripen</sub>ing, the viscose is filtered to remove any undissolved particles
- Degassing: Any bubbles of air are pressed from the viscose in a degassing process
- Extruding: The viscose solution is extruded through a spinneret, which resembles a shower head with many small holes
- Acid Bath: As the viscose exits the spinneret, it lands in a bath of sulfuric acid, resulting in the formation of rayon filaments: (C6H9O4O-SC-SNa)n + ½nH2SO4 → (C6H10O5)n + nCS2 + ½nNa2SO4
- Drawing: The rayon filaments are stretched, known as drawing, to straighten out the fibers
- Washing: The fibers are then washed to remove any residual chemicals
- Cutting: If filament fibers are desired the process ends here. The filaments are cut down when producing staple fibers
High wet modulus rayon (HWM) is a modified version of viscose that has a greater strength when wet. It also has the ability to be mercerized like cotton. HWM rayons are also known as "polynosic"[clarification needed] or can be identified by the trade name Modal.
High-tenacity rayon is another modified version of viscose that has almost twice the strength of HWM. This type of rayon is typically used for industrial purposes such as tire cord.
Cuprammonium rayon has properties similar to viscose but during production, the cellulose is combined with copper and ammonia (Schweizer's reagent). Due to the environmental effects of this production method, cuprammonium rayon is no longer produced in the United States.
Disposal and biodegradability
The biodegradability of fibers in soil burial and sewage sludge was evaluated by Korean researchers, and are listed here in order of decreasing biodegradability: rayon, cotton, acetate. The more water-repellent the rayon-based fabric is, the more slowly it will decompose. Silverfish can eat rayon.
A recent ocean survey found that rayon contributed to 56.9% of the total microplastic fibers found in deep ocean areas. 
Alternative to cotton
Rising cotton prices in 2010 led clothing makers to begin replacing cotton with rayon in their fabrics. As demand for rayon increases, companies such as Fortress Paper have been investing in pulp mills to increase production. Rayon now sells for as much as $2.70 per pound, which has led to an increase in the retail price of clothing made with rayon, yet rayon has a price advantage over cotton.
In early 2010, the U.S. Federal Trade Commission warned several retailers that six major manufacturers were falsely labeling rayon products as "bamboo", in order to appeal to environmentally conscious consumers. While rayon may be produced from bamboo as a raw material, and both rayon and bamboo may be used for similar fabrics (though natural bamboo is not as smooth), rayon is so far removed from bamboo by chemical processing that the two are entirely separate.
Trade names are used within the rayon industry to label the type of rayon in the product. Viscose Rayon was first produced in Coventry England in 1905 by Courtaulds.
Bemberg, is a trade name for cupramonium rayon developed by J. P. Bemberg. It performs much like viscose but has a smaller diameter and comes closest to silk in feel. Bemberg is now only produced in Italy due to United States Environmental Protection Agency regulations in the US. The fibers are finer than viscose rayon.
Modal and Tencel are widely used forms of rayon produced by Lenzing AG. Tencel, generic name lyocell, is made by a slightly different solvent recovery process, and is considered a different fiber by the US FTC. Tencel lyocell was first produced commercially by Courtaulds' Grimsby plant in England. The process which dissolves cellulose directly in amine oxide was developed by Courtaulds Research in Coventry.
Galaxy, Danufil, and Viloft are rayon brands produced by Kelheim Fibres.
Grasim of India is the largest producer of rayon in the world (claiming 24% market share). It has plants in Nagda, Kharach and Harihar – all in India, as well as joint ventures in Canada, Laos and China.
- "Rayon Fiber (Viscose)". afma.org.
- Kauffman, George B. (1993). "Rayon: the first semi-synthetic fiber product". Journal of Chemical Education 70 (11): 887. Bibcode:1993JChEd..70..887K. doi:10.1021/ed070p887.
- Editors, Time-Life (1991). Inventive Genius. New York: Time-Life Books. p. 52. ISBN 0-8094-7699-1.
- Over 100 years old and still going strong From Glanzstoff (artificial silk) factory to industry park. industriepark-oberbruch.de
- Verinigte Glanstoff Fabriken merged with the Nederlandse Kunstzijdefabrieken in 1929 to form the Algemene Kunstzijde Unie, AkzoNobel's predecessor
- J. P. Bemberg AG was one of the Verinigte Glanstoff Fabriken which merged into the Dutch based Algemene Kunstzijde Unie (AKU)--AkzoNobel today
- Kadolph, Sara J. and Langford, Anna L. (2001). Textiles (9 ed.). Prentice Hall. ISBN 0-13-025443-6.
- Karen L. LaBat and Carol J. Salusso (2003). Classifications & Analysis of Textiles: A Handbook. University of Minnesota.
- Joyce A. Smith. Rayon – The Multi-Faceted Fiber. Ohio State University Rayon Fact Sheet
- Park, Chung Hee; Kang, Yun Kyung; Im, Seung Soon (2004). "Biodegradability of cellulose fabrics". Journal of Applied Polymer Science 94: 248. doi:10.1002/app.20879.
- Abundance of microplastics in the world's deep seas (2014-12-16). Retrieved on 2014-12-17.
- Wirz, Matt (January 7, 2011) "The Touch, The Feel – Of Rayon," Wall Street Journal, Money and Investment section, p. c1
- Lipka, Mitch. (2011-01-12) Bamboo-zled: FTC says retailers fibbed about bamboo product claims. Walletpop.com. Retrieved on 2015-04-24.
- http://www.colbond.us/history.htm Acordis was a spinoff by AkzoNobel in 2000 after it had acquired Courtaulds. It was through AkzoNobel's original parent company's, the Nederlandse Kunstzijdefabriek (ENKA), joint venture with Rento Hofstede Crull 's De Vijf, named De Internationale Spinpot Exploitatie Maatschappij (ISEM) that the commercial production of rayon was made viable. Hofstede Crull had supplied the solution for the problem of manufacturing rayon with his Driving Device For A Centrifugal Spinning Machine in 1925 (1931 U.S. Patent 1,798,312). The ISEM was fully integrated with the Algemene Kunstzijde Unie, the Nederlandse Kunstzijdefabriek's successor, with the death of Hofstede Crull in 1938. (See AkzoNobel, American Enka Company, and also Rento Hofstede Crull.)
- "North American Rayon Corporation and American Bemberg Corporation" in the Tennessee Encyclopedia
- North American Rayon Corporation of Tennessee was an American subsidiary of J. P. Bemburg A.G. which was part of the Vereinigte Glanstoff Fabriken that were absorbed into the Dutch AKU, AkzoNobel today
- Grasim. Grasim (2004-08-06). Retrieved on 2012-08-22.
- For a review of all rayon production methods and markets see "Regenerated Cellulose Fibres", (book – Edited by C R Woodings) Hardback 2001, ISBN 1-85573-459-1, Woodhead Publishing Ltd.
- For a description of the production method at a factory in Germany in World War II, see Agnès Humbert, (tr. Barbara Mellor) Résistance: Memoirs of Occupied France, London, Bloomsbury Publishing PLC, 2008 ISBN 978-0-7475-9597-7 (American title: Resistance: A Frenchwoman's Journal of the War, Bloomsbury, USA, 2008) pp. 152–155
- For a complete set of photographs of the process see "The Story of Rayon" published by Courtaulds Ltd (1948)
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- History of Viscose Rayon and Artificial Silk
- Cellulose Based Plastics: Celluloid and Rayon
- The Production of Rayon by Courtaulds in England: Historic photos (1948)
- The Development of Tencel, a Pollution-free Rayon process by Courtaulds in England