How Is Rayon Fabric Made? Step-by-Step Chemistry Insights
Rayon is a regenerated cellulose fiber produced from natural cellulose sources, such as wood and agricultural products associated with it. Rayon material has the same molecular structure as cellulose. Viscose rayon fabric could mean:
A Cellulose Viscous Solution
A rayon synonym
A particular term for viscose rayon, rayon developed using the viscose method
There are various forms and grades of viscose fibers and films. The feel and texture of natural fibers such as silk, wool, cotton, and linen are imitated by others. The kinds which imitate silk are often referred to as artificial silk. The fiber is used for garments and other uses to produce textiles.
Discovery of Fiber
By chemically processing rags and wood pulp, Hilaire de Chardonnet discovered the process of deriving functional fiber from cellulose in 1885. It was first produced by DuPont and sold there. There was a massive transformation in the textile industry since the introduction of DuPont to the market. DuPont companies have begun manufacturing man-made fabrics such as nylon. Regardless of the attempts made to make cost-effective artificial silk by other scientists. It is sometimes considered that Chardonnet is the father of rayon fabric. Soon, rayon became one of the most significant fibers in the carpet and home textile industries.
Production of Rayon Fabric
While rayon is made from a natural material called cellulose, since the fiber is chemically altered according to the final product's specifications and demands, it is considered to be a man-made fiber. The first company to manufacture man-made rayon was DuPont. Silk was considered a royal cloth at that period, and only the royal family had the luxury of using it in the Yang dynasty. Nylon and rayon became a significant fabric for making clothes after some time.
Properties of Rayon
Rayon material is a durable fiber and is commonly proclaimed to have the same comfort properties as natural fibers, while nylon is often more like the drape and slipperiness of rayon textiles. The feel and texture of silk, wool, cotton, and linen can be imitated by this in a wide variety of colours, the fibers are easily dyed.
Rayon cloth is soft, smooth, cool, comfortable, and highly absorbent, but they do not always insulate body heat, making them suitable for use in hot and humid climates, while also making their 'hand' (feel) cool and almost slimy to the touch.
Lengthwise, normal rayon cloth has lines called striations, and an indented circular form is its cross-section. HWM and cupra rayon cross-sections are rounder.
The filament rayon yarn ranges between 80 and 980 filaments per yarn and varies between 40 and 5000 deniers in size.
Staple fibers are mechanically or chemically crimped and range from 1.5 to 15 deniers.
Did You Know?
Difference between Rayon Fabric and Viscose
Rayon is a fabric made from plant cellulose that undergoes many chemical processes, while viscose is a type of viscose-based rayon.
Although viscose appears like silk and feels like cotton, rayon is highly absorbent and simple to dye.
Both rayon and viscose are made in the same process, but the materials used are different. Although rayon can be made from a range of plants with cellulose, viscose is made from wood pulp or cotton linter.
Viscose rayon can also be less durable because it is manufactured with a high concentration of caustic soda, whereas other forms of rayon use less than other types of rayon.
FAQs on Rayon Fabric: Chemistry, Production, and Key Properties
1. What exactly is rayon fabric and why is it considered semi-synthetic?
Rayon is a fabric made from regenerated cellulose fibres, which are typically sourced from natural materials like wood pulp. It is considered semi-synthetic because while its raw material (cellulose) is natural, it must undergo significant chemical processing to be transformed into a usable fibre. This combination of a natural origin with an intensive man-made manufacturing process distinguishes it from purely natural fibres like cotton or purely synthetic ones like polyester.
2. How is rayon made from a natural source like wood pulp?
Rayon is typically produced using the viscose process. In this method, wood pulp is chemically treated with sodium hydroxide and then carbon disulphide to create a thick, honey-like liquid called viscose. This solution is then forced through a spinneret, which has tiny holes, into a bath of dilute sulphuric acid. The acid causes the cellulose to solidify and regenerate into fine filaments, which are then washed, bleached, and spun into threads to be woven into rayon fabric.
3. Why is rayon often called 'artificial silk'?
Rayon earned the nickname 'artificial silk' because its properties closely resemble those of natural silk at a much lower cost. It shares silk's characteristic lustre, soft texture, and elegant drape. This makes it an excellent, affordable alternative for creating clothing and textiles that have a luxurious look and feel, such as dresses, blouses, and decorative curtains.
4. What are the main advantages of using rayon fabric over cotton?
While both are plant-based, rayon has some distinct advantages over cotton:
- Higher Absorbency: Rayon is more absorbent than cotton, allowing it to wick moisture away from the skin effectively, which can enhance comfort.
- Lustre and Drape: It possesses a natural sheen and a fluid drape that is more similar to silk, giving garments a more graceful and luxurious appearance.
- Vibrant Colours: Rayon fibres accept dyes exceptionally well, resulting in deep, rich colours that are often more brilliant than those in cotton fabrics.
5. What are the key disadvantages or limitations of rayon?
Rayon has a few significant limitations that are important to consider:
- Weak When Wet: Rayon loses a substantial amount of its tensile strength when it is wet, making it fragile and prone to stretching or tearing during washing.
- Prone to Wrinkling: The fabric wrinkles very easily and often requires careful ironing at a low temperature to maintain a smooth appearance.
- Environmental Impact: The traditional viscose manufacturing process uses toxic chemicals that can pollute air and water and pose health risks to factory workers if not managed with strict environmental controls.
6. Is rayon fabric a good choice for wearing in summer?
Yes, rayon is an excellent fabric for summer clothing. Its fibres are highly absorbent and breathable, which helps to draw sweat away from the body and allows air to circulate, keeping the wearer cool and comfortable in hot and humid weather. Its lightweight and smooth texture also feels pleasant against the skin.
7. What are some common examples of items made from rayon?
Due to its versatility and silk-like feel, rayon is used in a wide variety of products. Common examples include:
- Apparel: Dresses, blouses, shirts, skirts, trousers, and as a lining material in jackets and suits.
- Home Furnishings: Curtains, drapes, bed sheets, and tablecloths.
- Industrial Applications: In the past, it was used for tire cords and is still used in some medical and hygiene products.
8. How can one distinguish rayon from other fabrics like silk or polyester?
You can perform a few simple tests to identify rayon:
- The Feel Test: Rayon feels smooth, cool, and a bit slippery, much like silk. However, pure silk often has a unique warmth to it that rayon lacks. Polyester can also feel smooth but often has a more artificial or less 'breathable' feel.
- The Wrinkle Test: Crumple a piece of the fabric tightly in your hand. Rayon wrinkles very easily, whereas polyester is highly wrinkle-resistant. Silk wrinkles but often less severely than rayon.
- The Burn Test (use extreme caution): Rayon burns quickly with a yellow flame, smells like burning paper or leaves, and leaves behind a soft, grey ash. Silk smoulders, smells like burning hair, and self-extinguishes. Polyester melts into a hard, black bead and has a chemical smell.
9. What is the difference between types of rayon, such as viscose, modal, and lyocell?
While all are types of rayon, they differ in production and properties:
- Viscose Rayon: The most common and oldest type. It's versatile but weak when wet and its production has significant environmental drawbacks.
- Modal: A second-generation rayon with higher strength, especially when wet. It's known for its exceptional softness and is often blended with other fibres like cotton and spandex.
- Lyocell (e.g., Tencel): A more recent type produced using a more sustainable, closed-loop process that recycles the solvent. It is strong, absorbent, and less prone to wrinkling than other rayons.
10. Despite being sourced from plants, why can rayon production be harmful to the environment?
The environmental harm associated with rayon comes from its chemical-intensive manufacturing process, not its natural source. The traditional viscose method requires toxic chemicals like carbon disulphide, a known neurotoxin, to dissolve the wood pulp. If these chemicals are not properly contained and recycled, their release into the air and water can cause severe pollution and endanger the health of workers and nearby communities. This is why more modern, eco-friendly versions like lyocell are becoming more popular.
