In the 20th century, people have been looking for low-cost carpet fibers that can match the characteristics and properties of wool. There are two types of man-made fibers, recycled fiber and synthetic fiber.
Regenerated fiber has the same basic chemical composition as raw materials, but its physical form is different. For example, viscose rayon is made from cellulose in wood pulp.
Synthetic fibers are made of polymers composed of simple molecules. Raw materials from the petrochemical industry are used to extrude fibers by forcing a thick chemical mixture in a hot-melt state through micropores in a device similar to a shower Rose (called a spinneret). The resulting filaments solidify and twist together to form a yarn.
Synthetic fibers can be "designed" to show special quality for a specific purpose in the final product. They can be manufactured in various denier sizes (i.e. diameters) and can be used as continuous filaments or staple fibers. Heat setting or texturing introduces artificial crimping. Many fibers are spun into cross sections of different shapes and may have bright or matte finishes. A matte finish is obtained by adding white pigments such as titanium dioxide to the melt before extrusion, or by inserting small voids in the fiber to scatter light. Coating the fiber with fluorocarbon film helps to prevent dirt and stains from adhering to the surface and spreading.
Nylon (or polyamide) is lighter than any other carpet fiber, so less mass of this fiber is required in the carpet structure. Nylon fibers absorb very little water. Nylon's heat setting curl provides additional elasticity and coverage, trying to imitate the excellent elasticity of wool.
Polypropylene is the latest carpet fiber. The filament formed by polypropylene polymer has similar strength to nylon. Simple hydrocarbon molecular chains are arranged in order.
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