Sintepon: features and subtleties of care

Insulation has always been a sought-after material when sewing winter and demi-season clothing. Until the 80s of the XX century, cutters used natural batting as a heater for jackets and coats. Batting, being a widespread, extremely practical and popular material, has many drawbacks, so its analogue, synthetic winterizer, was invented.

On September 15, 2008, the Federal Service for Intellectual Property, Patents and Trademarks registered a patent on the application under the number 2008136716/12 for the invention of synthetic winterizer - a nonwoven material with a random arrangement of fibers. The synthetic analogue of batting for sanitary conditions met a number of conflicting clothing requirements, namely:

• lining made of synthetic winterizer, thin, soft and light;
• outerwear with a lining of non-woven polyester fiber retains heat well;
• synthetic non-woven material is easily washed at home and treated with reagents during dry cleaning;
• the batting analog does not ignite when hot ash from a cigarette gets on it;
• when heated above + 40 ° C, exposure to precipitation and sweat, toxic and strongly smelling chemicals are not released;
• synthetic winterizer is not destroyed by precipitation, with prolonged exposure to mechanical stress and open flame.

A synthetic winterizer is an artificial non-woven batting substitute, which is made of polyester fiber or granules in a thermal, adhesive or needle-punched manner. Sintepon or polyethylene terephthalate completely replaces batting. A heater is made from sintepon, it is also used as a filter for fine purification of drinking water. Industrial production technology allows the production of synthetic winterizer from polyethylene granules, as well as from waste products - bags and bottles. The line for the production of syntepon thermally consists of the following devices:

• compartment for loading raw materials;
• unit for grinding raw materials and irrigation with mineral oil;
• unit for combing fibers;
• induction heating furnace;
• unit for sintepon packaging.

Granular polyethylene terephthalate or crushed plastic is poured into the loading compartment. Mechanical gears with circular knives grind the raw materials and moisten with mineral oil from the spray head. The combing unit combs the fibers in length, removes debris and lumps before feeding for sintering in the induction furnace. The air stream feeds the fibers into an induction furnace heated to a temperature of from +380 to + 420 ° C, inside which a ceramic disk rotates at high speed.

In contact with the disk from a high temperature, the fibers melt, the centrifugal force forms about 1 micron thick threads from the melt. A stream of air from a powerful fan blows the threads into the chamber, from which the heated rolls form a synthetic winterizer layer up to 5 centimeters thick and feed it for stacking in plastic film bags.

This filler has the following advantages:

• low density;
• does not absorb moisture;
• not blown by the wind;
• does not burn under the influence of an open flame;
• when heated and in contact with water does not emit toxic substances;
• synthetic winterizer products are light and soft;
• keeps heat well;
• does not require special care;
• low cost;
• It does not fall lumps and does not deform.

But it is also worth highlighting the disadvantages, such as:

• Do not dry clean and wash in water warmer + 40C;
• with frequent washing, it gradually loses its density;
• latex glue used for the manufacture of adhesive sintepon, represents a real danger to human health.

The synthetic winterizer is used as a heater when sewing winter coats, jackets and coats. It is also used for stuffing mattresses, pillows, soft toys and technological compartments in the doors of refrigerators and cars. Sintepon cotton wool and single-layer sintepon plates are used as insulation for winter clothes, warm blankets, sleeping bags, car interiors, children's and medical thermal underwear. From the synthetic winterizer blocks wrapped in aluminum foil, a heater is made for a refrigerator and thermal insulation for a thermos flask.

A protective layer of a heat-resistant suit for rescuers of the Ministry of Emergencies of Russia was made of aluminum foil packages with synthetic winterizer fibers. Cellophane bags filled inside with thin layers of synthetic winterizer with the addition of boron, cadmium, molybdenum and lead salts fill the compartments of the radiation protection suit with a high level of protection. It is used by astronauts, fighter pilots, members of polar expeditions, climbers and emergency brigade workers at nuclear power plants. The small distance between the polyester fibers, commensurate with the size of the kitchen salt molecule, makes it possible to produce a high-quality filter from sintepon for fine purification of drinking water without activated carbon and ion-exchange resins.

According to the results of spectral analysis of the finished products, the following approximate chemical composition of syntepon was determined:

• hollow polyethylene fibers - up to 30%;
• hot glue polyethylene fibers - up to 25%;
• other polyester fibers - up to 45%.

The exact proportion of the components in the finished product and even their presence are not regulated by any documents.According to experts, the composition of sintepon depends not only on the production technology and quality of the feedstock. Of great importance is the gas composition of the atmosphere and the temperature in the chamber where the sintering of the polymer fibers takes place. The physical and mechanical properties of a synthetic winterizer from granular polyethylene largely depend on it. Syntepon production is carried out in several ways.

• Thermal. Under the influence of high temperature, the polyester fibers melt and sinter among themselves at the points of contact. The material obtained in this way has increased wear resistance, poor thermal conductivity and increased rigidity. He goes on the manufacture of mattresses, folding chairs and office furniture.
• Glue. Separate polyester fibers are glued layer-by-layer with latex glue, which is obtained by dissolving rubber in a hot concentrated ammonia solution. Sodium polyacrylate is used as a thickener. When the synthetic winterizer obtained by the adhesive method is heated to a temperature above + 40 ° C, toxic volatile compounds of ammonia, phenol and carbolic acid are released into the air, which cause its specific smell. According to sanitary standards, an adhesive synthetic winterizer can not be used for the manufacture of winter clothes for children, pillows and soft toys.
• Needle Punch. Polyester fiber is stitched on a special sewing machine with kapron thread. This technology is used in the manufacture of lining for winter and demi-season clothing, as well as in the manufacture of quilts.

According to the manufacturers, supported by international certificates and diplomas, the synthetic winterizer is made from polyester fiber by drawing the finest threads from the melt with their subsequent pressing or gluing into layers or granules. In fact, in most cases, manufacturers, frankly, brazenly lie to the buyer looking directly into the eyes, using the following points:

• standing near the counter, the buyer can not look under the outer cover of the jacket or overalls and touch the lining material with his hand;
• currently in Russia and in foreign countries there is no GOST or other documents that clearly regulate the chemical composition, production technology and physical properties of this material.

Using these moments, manufacturers of syntepon, obsessed with the desire to get maximum savings at all costs, do not disdain anything, starting from an elementary violation of production technology and ending with the use of illegal chemicals and additives. These points should be taken into account for young mothers who buy cheap overalls and synthetic winter jackets for their babies with Made-in-China or Made-in-Europe labels on the markets. Instead of a layer of warm and safe holofiber or synthetic winterizer, under a bright flap of nylon in these clothes mineral wool, glass wool or ordinary foam rubber can be hidden at best.

The compounds of polyester and polyamide do not enter into chemical reactions with oxygen and nitrogen of the air, do not dissolve in water even in the presence of catalysts. Garbage recycling plants in Russia and around the world burn thousands of tons of synthetic fabrics daily in furnaces, saturating the already polluted atmosphere with highly toxic compounds of phenol, benzene and acetaldehyde. The ecological problem of the complete utilization of polyester resins and their derivatives is very similar to the situation with DDT, which was found in the liver of Arctic whales and penguins at the end of the 20th century after the massive use of dust in vegetable gardens and fields.

According to the report of Swedish doctors at the International Scientific and Practical Conference, a whole group of materials made on the basis of PVC, caprolactam and polyesters should be immediately banned from being used as raw materials for the production of clothes, bedding, dishes and household items.

According to statistical and experimental data that scientists have received, these substances affect the process of DNA replication during cell division, thereby causing irreparable harm to the health of not only its owner, but also to hereditary diseases, metabolic disorders in subsequent generations and even infertility.

The synthetic winterizer is a nonwoven fabric. Depending on the production technology, specialists distinguish the following types of synthetic winterizer:

• wool (sherstepon);
• sintepuh;
• holofiber.

It is worth considering each of the types of synthetic winterizer in more detail.

Currently, there are several varieties of holofiber.

• Hollofiber Soft. High air permeability does not interfere with thermoregulation, retains shape after repeated washing. This material is used for tailoring high-quality model clothes, insulated clothing for athletes, suits for climbers and tourists, as well as for children's clothing sets.
• Hollofiber fuel and energy complex. This is a professional insulation for winter clothing for oil and gas workers. It is resistant to solvents and fuels and lubricants, does not crumple during washing, and is resistant to low temperature. This option is used for tailoring workwear and personal protective equipment.
• Hollofiber Stroy. This is a low temperature insulation for walls and floors. It is recommended to use it as a thermal liner or interventional seal. Its advantages include low thermal conductivity and good sound insulation.

• Hollofiber Volumetric. This is a popular insulation for children's clothing. It neither causes allergic reactions, nor wrinkles during socks and does not burn when in direct contact with an open flame.
• Hollofiber Hard. This option is used in construction practice as thermal insulation. It neither shrinks nor absorbs moisture and does not form dust.
• Hollofiber Medium. It is used for the manufacture of children's kits, envelopes for discharge from the hospital, the sides in the crib, as well as pillows and mattresses for babies.

A synthetic winterizer with the addition of camel or sheep wool is used in the manufacture of belts from dog, camel or sheep wool. Belts have a persistent therapeutic effect without tablets, ointments and injections for diseases of the musculoskeletal system (bruises and fractures, neuralgia, radiculitis, arthritis, arthrosis, osteochondrosis, neuritis). The belt does not have a stimulating effect on the growth of a cancerous tumor. Athletes who use warming leggings and knee pads made of sherstepon with the addition of viscose are used by athletes during intensive outdoor activities in the winter. Underwear is added from sherstepon with the addition of 10% lavsan, which are worn by high-altitude installers in the construction of power lines and fitters during routine maintenance to replace insulators on the supports of high-voltage power lines in the cold season outside the Arctic Circle, in Siberia, Yakutia and the Far East.

The fluffed synthetic winterizer with the addition of natural fluff is used to fill pillows, overalls and a winter blanket. It does not stray into lumps, does not require periodic drying in the sun and does not absorb unpleasant odors.

The good thermal insulation properties of the synthetic winterizer make it an indispensable filler for children's winter clothes, suits of astronauts, polar explorers, divers, paratroopers, mountain rescuers, skiers, climbers, EMERCOM employees. Winter jackets, overalls and overalls well protect the human body from overheating and hypothermia. The padding from the synthetic winterizer is resistant to compression, is not afraid of direct contact with sparks, ashes from cigarettes and prolonged exposure to open fire. Dense synthetic winterizer is used as a filler in the manufacture of upholstered furniture. They are filled with piers and technological niches in modern houses with underfloor heating.

The synthetic winterizer does not lose its properties under mechanical stress, does not fall lumps and does not absorb unpleasant odors, unlike its predecessors - batting, felt and foam rubber. In order for the insulation pad from sintepon to retain heat well and serve as long as possible, the following rules must be observed:

• for washing a jacket or coat lined with synthetic winterizer, it is recommended to use a detergent for synthetic fibers;
• washing powder with enzymes, bleaches and dyes should be used very carefully;
• the use of chlorine-releasing substances is strictly prohibited;
• with severe contamination of the padding from sintepon it is best to give the clothes dry cleaning, which guarantees the quality of the wash and the safety of the clothes;
• it is possible to wash clothes with a padding polyester in a washing machine at a temperature of no higher than +40 degrees;

• so that the sintepon does not roll into lumps after washing, you can not rub the clothes in the washing solution with your hands; to straighten and fluff the crumpled lining after such washing will be quite difficult;
• if the sintepon, in spite of all the precautions, has gotten into lumps - you need to send the jacket or coat again to the washing machine, after having put several tennis balls there, which, when washing in the drum, can whip up the compacted places.

The washing process is as follows:

• before washing, the product must be turned inside out;
• stains must be removed with laundry soap or a special stain remover;
• Before washing, be sure to lay out ball pens, felt-tip pens, markers from pockets;
• clothes should be packaged in a fabric bag before washing; it will protect clothes and lining from synthetic winterizer from mechanical destruction;
• the temperature of the solution in the washing machine should not exceed + 40 ° C;
• the washing mode switch must be set to “Synthetics”;
• to avoid soapy halos, items should be rinsed well after washing;
• you need to dry things horizontally on a large towel.

In order to quilting the fabric at home, we perform the following steps step by step:

• we take two identical flaps of fabric for the top and bottom and the same size piece of padding polyester;
• we move the rulers to set the distance between the lines from 2 to 8 centimeters;
• remove the standard foot from the adapter of the sewing machine and set the walking;
• fasten the new foot with a screw;
• we check the supply of material and the quality of the stitch on a flap of fabric - the teeth on the sole of the foot should move synchronously with the teeth of the conveyor, the stitch loop should be in the thickness of the material; if necessary, adjust the stitch length and thread tension;
• on both sides of the lining, apply a small amount of glue from the spray gun and apply material to it from the front and the wrong side;
• mark with chalk lines for the line;
• we sew the material crosswise, moving from center to edge;
• when moving to the next seam, make sure that the material does not move;
• if necessary, use a line with decorative loops at the edges of the blanket.

About syntepon, what it is and how it is made, see the next video.