Conditions necessary for the rapid formaldehyde curing of zein fibers were investigated and a continuous two-stage curing process was developed. The first stage (precuring) consists of a mild cure to introduce approximately 0.75 percent formaldehyde into the fiber and produces, after stretching, a fine-diameter fiber of exceptional strength and elasticity. The second stage (post-curing) consists of a strong cure to introduce about 3.0 percent additional formaldehyde into the stretched fiber to stabilize its length.Formaldehyde is bound under both alkaline and acid conditions, but it is only under acid conditions that any curing occurs. Ammonium salts act as catalysts for the reaction in the pH range 0 to 4 and the resulting fibers are stable to boiling in mild alkali. When cured under highly acidic conditions (below pH 0), the fibers are stable to both acid and alkaline boiling.
THE PROTEIN-FORMALDEHYDE REAC-TION is a basic reaction in the preparation of all the azlon fibers. Although the reaction is complicated and leaves much to be desired, no other reaction seems to accomplish the same purpose. Various authors [6,9,11,15] have reviewed the recent literature, and show that every reactive group in proteins, with the possible exception of the carboxyl group, may bind formaldehyde. Zein has only recently gained industrial importance and the technical literature covering its utilization is largely limited to patents.The reaction of formaldehyde with zein is considerably different from its reaction with other proteins because of the limited number of reactive groups present. The presence of formaldehyde in an alcoholic or alkaline dispersion of zein does not cause gelation but acts, instead, to stabilize the dispersion. The lack of any evidence of a curing reaction when zein is treated with formaldehyde under the conditions used for other proteins has led to the belief that zein is not very reactive. Part of the difficulty has been the failure to distinguish between a reaction with formaldehyde and a reaction which resulted in a curing of the protein. For zein, the conditions under which the formaldehyde reaction is carried out are of the utmost importance because entirely different or even opposite results are obtainable when conditions are changed. Swallen [17] has shown the catalyzing effect of acids, ammonium salts, and amines on the curing of zein films and plastics. The importance of salts in catalyzing the curing of other proteins has not been recorded in the literature. It is surprising to find that many workers have not considered the control of pH to be important in the study of the protein-formaldehyde reaction.Swallen [16] cured zein fibers by baking the formaldehyde-treated fiber for 8 to 10 hours at 60°-90°C. Meigs [13] indicated that hardening of zein fibers could be obtained with formaldehyde or other known protein curing agents. Our preliminary work soon indicated that besides the factors of time, temperature, and concentration of formaldehyde, the factors of pH and salt concentration were very impo...