Sintepon: features and subtleties of care

Insulation has always been a popular material when sewing winter and demi-season clothing. Until the 80s of the 20th century, cutters used natural batting as a heater for coats and coats. Batting, being a widespread, extremely practical and sought-after material, has many drawbacks, so its counterpart, a 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 a padding polyester - a nonwoven material with a random arrangement of fibers. According to sanitary and hygienic conditions, the synthetic analogue of batting satisfied a number of conflicting requirements for clothing, namely:

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

The synthetic winterizer is an artificial non-woven substitute of batting which is made of polyester fiber or granules in the thermal, glue or needle-punched way. The synthetic winterizer or polyethylene terephthalate completely replaces batting. Insulation is made of synthetic winterizer, it is also used as a filter for fine purification of drinking water. The technology of industrial production allows to produce synthetic winterizer from polyethylene granules, as well as from garbage - packages and bottles. The line for the production of a synthetic winterizer by thermal method consists of the following devices:

• compartment for loading raw materials;
• unit for grinding raw materials and irrigation with mineral oil;
• fiber combing unit;
• induction heating furnace;
• the unit for packing of a synthetic winterizer.

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

In contact with the disk from a high temperature, the fibers melt, the centrifugal force forms from the melt a thread with a thickness of about 1 micron. The air flow from the powerful fan blows the filaments into the chamber, from which the heated rolls form a layer of synthetic winterizer with a thickness of up to 5 centimeters and serves it for packing in plastic 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;
• products from a synthetic winterizer not heavy and soft;
• retains heat well;
• does not require special care;
• low cost;
• not lumpy and not deformed.

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

• Do not dry clean and wash in water warmer than + 40C;
• with frequent washings it gradually loses its density;
• Latex glue used for the manufacture of glue padding polyester represents a real danger to human health.

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

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

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

• hollow polyethylene fibers - up to 30%;
• thermoglue 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 is not regulated by any documents. According to experts, the composition of the padding polyester depends not only on the production technology and the quality of the feedstock. Of great importance is the gas composition of the atmosphere and the temperature in the chamber, where sintering of polymer fibers takes place. The method of producing a synthetic winterizer from granulated polyethylene largely determines its physical and mechanical properties. Production of synthetic winterizer is carried out in several ways.

• Thermal. Under the influence of high temperature, polyester fibers melt and sinter together among themselves at the points of contact. The material obtained in this way has a high wear resistance, poor thermal conductivity and increased rigidity. He goes to the manufacture of mattresses, folding chairs and office furniture.
• Glue. The individual fibers of the polyester are glued together in layers with latex glue, which is obtained by dissolving rubber in 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, poisonous volatile compounds of ammonia, phenol and carbolic acid are released into the air, which cause its peculiar smell. According to sanitary standards, glue synthepon cannot be used for making winter clothing for children, pillows and soft toys.
• Needle punch. Polyester fiber is stitched on a special sewing machine with nylon thread. This technology is used in the production of lining for winter and demi-season clothing, as well as when sewing a quilt.

According to the manufacturers, supported by international certificates and diplomas, the synthetic winterizer is made from polyester fiber by pulling 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 straight into their eyes, using the following points:

• when standing near the counter, the buyer cannot 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.

Taking advantage of these moments, manufacturers of sintepon, obsessed with the desire to get the maximum savings at any cost, do not disdain anything, starting from an elementary violation of production technology and ending with the use of prohibited chemicals according to the law and additives. These moments should be taken into account for young mothers who buy cheap overalls and jackets on the padding polyester 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 sintepon, mineral wool, glass wool or regular foam can be hidden under the bright nylon flap in these clothes.

The compounds of polyester and polyamide do not enter into chemical reactions with oxygen and nitrogen of air, they do not dissolve in water even in the presence of catalysts. Waste disposal plants in Russia and around the world burn thousands of tons of synthetic fabrics in kilns daily, saturating the already polluted atmosphere with highly toxic compounds of phenol, benzene and acetaldehyde. The environmental problem of complete utilization of polyester resins and their derivatives is very similar to the situation with DDT, which was discovered 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 the Swedish physicians at the International Scientific and Practical Conference, a whole group of materials based on PVC, caprolactam and polyesters should be immediately banned as raw materials for the production of clothing, bedding, dishes and household items.

According to the statistical and experimental data that scientists have received, these substances affect the DNA replication process during cell division, which causes irreparable harm to the health not only of 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 padding polyester:

• wool (sherstepon);
• sintepukh;
• holofiber

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

Currently, there are several types of holofiber.

• Hollofiber Soft. High air permeability does not interfere with thermoregulation, retains its shape after repeated washes. This material is used for tailoring high quality fashion clothing, insulated clothing for athletes, suits for climbers and tourists, as well as sets of children's clothing.
• Hollofayber TEK. This is a professional heater for winter clothes of oil and gas workers. It is resistant to solvents and fuels and lubricants, does not collapse when washed, and is resistant to low temperatures. This option is used for sewing clothing and personal protective equipment.
• Holofiber Stroy. It is a low-temperature insulation for walls and floors. It is recommended to use as a thermofiller or mezhventsovy sealant. Its advantages include low thermal conductivity and good sound insulation.

• Holofiber Volumetrics. This is a popular insulation for children's clothing. It does not cause allergic reactions, nor is it crushed during wear, 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.
• Holofiber Medium. It is used for the manufacture of baby sets, envelopes for discharge from the maternity hospital, skirting in a crib, as well as pillows and mattresses for babies.

The 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 pills, ointments and injections for diseases of the musculoskeletal system (bruises and fractures, neuralgia, sciatica, arthritis, arthrosis, osteochondrosis, and neuritis). The belt does not have a stimulating effect on the growth of a cancer. Athletes use warming leggings and knee-pads made of sherstepon with the addition of viscose during intensive outdoor activities in the winter. Underwear with 10% of lavsan is made of woolen cloth, worn by high-altitude installers at the construction of power lines and fitters during routine maintenance work on replacing insulators on high-voltage power line poles in the cold season around the Arctic Circle, in Siberia, Yakutia and the Far East.

Fluff synthetic winterizer with the addition of natural fluff is used to fill pillows, overalls and a winter blanket. It does not clump together, does not require periodic drying in the sun and does not absorb unpleasant odors.

The good thermal insulation properties of the padding polyester make it an indispensable filler for children's winter clothes, cosmonauts' suits, polar explorers, divers, paratroopers, mountain rescuers, skiers, climbers, employees of the EMERCOM of Russia. Winter jackets, overalls and overalls well protect the human body from overheating and overcooling. The lining of the padding polyester is resistant to compression, is not afraid of direct sparks, ash 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 homes with a warm floor.

The synthetic winterizer does not lose its properties under mechanical load, does not fall down into lumps and does not absorb unpleasant odors, unlike its predecessors - batting, felt and foam rubber. In order to keep the heat insulation material from a sintepon well kept warm and serve as long as possible, you need to follow the following rules:

• for washing a jacket or coat with a lining of synthetic winterizer, it is recommended to use a detergent for washing synthetic fibers;
• enzyme washing powder, bleaching agents and coloring matter should be applied very carefully;
• the use of chlorine release agents is strictly prohibited;
• in case of severe contamination of the lining of the padding polyester, it is best to dry out the clothes, which guarantees the quality of washing and the safety of clothes;
• washing clothes in a washing machine with lining of synthetic winterizer can be at a temperature not higher than +40 degrees;

• so that the synthetic winterizer does not roll into lumps after washing, you should not rub the clothes in the washing solution with your hands; straightening and fluffing up the crumpled lining after such a wash will be very difficult;
• if the synthetic winterizer, despite all the precautions, is lumped together - you need to send the jacket or coat back to the washing machine, after having placed there several tennis balls, which, when washed in the drum, will be able to beat the tight places.

The washing process is performed in the following way:

• before washing the product must be turned inside out;
• stains must be removed with soap or a special stain remover;
• before washing, be sure to put out of the pockets ballpoint pens, felt-tip pens, markers;
• clothes before washing need to pack in a cloth bag; it protects clothing and lining of synthetic winterizer from mechanical damage;
• the temperature of the solution in the washing machine should not exceed + 40 ° C;
• switch washing modes must be set to "Synthetic";
• to avoid soap ghosting, rinse things well after washing;
• dry things in a horizontal position on a large towel.

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

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

About sintepon, what it is and how it is done, see the next video.