Method for fiberizing membrane, resulting fiber products, and building materials containing fiber products

Abstract

The present disclosure provides a method for fiberizing membrane. The method includes providing a membrane; patterning the membrane by recessing it to form several recesses, wherein these recesses are arranged separately in a first direction; and applying an external force to fracture the patterned membrane, thereby forming several fibers with a predetermined size. These recesses provide breakpoint areas when the membrane fractures.

Description

[Technical Field]

[0001] This disclosure relates to a method for fiberizing a membrane material, the resulting fiber product, and building materials containing the fiber product. [Previous Technology]

[0002] Existing fiber production methods, such as wet spinning, dry spinning, and melt spinning, require the use of many chemicals, resulting in high chemical costs, generating large amounts of wastewater and causing serious environmental damage. Furthermore, they require high-temperature processes that consume significant amounts of energy, increasing production costs and wasting considerable energy. Therefore, existing fiber manufacturing processes are neither economical nor environmentally friendly overall. [Summary of the Invention]

[0003] In some embodiments, this disclosure provides a method for fiberizing a membrane material, including providing a membrane material; patterning the membrane material by recessing the membrane material to form a plurality of recesses, the recesses being spaced apart in a first direction; and applying an external force to rupture the membrane material to form a plurality of fiber members having a predetermined size, wherein the recesses provide a break point region when the membrane material ruptures.

[0004] In some embodiments, this disclosure provides a fiber product comprising a plurality of fiber elements made of a polymer film material, wherein each fiber element has a main body portion and at least one extension portion located at one end of the main body portion, the upper surface of the main body portion being higher than the upper surface of the extension portion.

[0005] In some embodiments, this disclosure provides a building material comprising the fiber products described above.

Implementation Method

[0006] The following disclosure provides many different embodiments or examples to illustrate different components of the embodiments of this disclosure. Specific examples of the components and their arrangements will be disclosed below to simplify the description of this disclosure. Of course, these specific examples are not intended to limit this disclosure. For example, if the following disclosure describes forming a first component on or above a second component, it means that it includes embodiments where the formed first and second components are in direct contact, and also includes embodiments where additional components can be formed between the first and second components, in which case the first and second components are not in direct contact. Furthermore, the various examples in this disclosure may use repeated reference numerals and / or words. These repeated numerals or words are intended to simplify and clarify this disclosure and are not intended to limit the various embodiments and / or the relationships between the described configurations.

[0007] Furthermore, to facilitate the description of the relationship between one element or component and another element or component(s) in the diagram, spatial relative terms may be used, such as "below," "under," "above," "above," and similar terms. In addition to the orientation shown in the diagram, spatial relative terms also cover different orientations of the structure or device in use or operation. When the structure or device is rotated to a different orientation (e.g., rotated 90 degrees or other orientations), the spatial relative adjectives used therein will also be interpreted according to the orientation after the rotation.

[0008] Here, the terms "about," "approximately," and "roughly" generally mean within 20% of a given value or range, preferably within 10%, and even more preferably within 5%, or within 3%, or within 2%, or within 1%, or within 0.5%. It should be noted that the quantities provided in the specification are approximate quantities, that is, even without specific instructions to use "about," "approximately," or "roughly," the meaning of "about," "approximately," or "roughly" may still be implied.

[0009] The following describes some variations of the embodiments. Although the steps in some embodiments are performed in a specific order, these steps may also be performed in other logical orders. Additional process steps may be included before, during, and / or after some process steps described in the embodiments, and some process steps described in some embodiments may be replaced or deleted in the methods of other embodiments. Furthermore, it is understood that other components may be added to the apparatus or system in the embodiments illustrated by the present invention, or some components may be replaced or omitted.

[0010] This disclosure provides a method for fiberizing membrane material, the resulting fiber product, and building materials containing the fiber product. The membrane material fiberizing method proposed in the embodiments of this disclosure involves first performing a patterning process on the membrane material to create breakage points, after which the patterned membrane material can be broken into fiber parts of the required width using only simple external force. The method proposed in the embodiments allows for precise control of the length and width of the resulting fiber parts. Furthermore, according to the method proposed in the embodiments, the membrane material can be pre-wound after the patterning process, effectively saving storage space, warehouse storage volume, and transportation volume. Moreover, the method proposed in the embodiments is simple to manufacture, has low chemical costs, produces little waste liquid, and does not require excessively high process temperatures. Therefore, when the method of the embodiments is applied to produce fiber parts as needed, the process can be simplified, process time saved, process efficiency significantly improved, and the process can be carried out at relatively low temperatures (e.g., between room temperature and drying oven temperature ≤ 100°C), offering numerous benefits such as energy saving, environmental friendliness, and reduced production costs. Incorporating the fiber products obtained in the examples into building materials, such as cement, concrete raw materials, or asphalt concrete, can improve the properties of the building materials.

[0011] Figure 1 shows a flowchart of a method 10 for membrane fiberization according to some embodiments of the present invention. Figure 2 shows a schematic diagram of a membrane fiberization process according to some embodiments of the present invention. Figures 1 and 2 can be referred to simultaneously.

[0012] According to some embodiments, referring to step 11 of FIG1, a membrane material is provided. This membrane material is, for example, a continuous membrane material made of a polymer. According to some embodiments, the provided membrane material is, for example, a modified membrane material. In this embodiment, a polyvinyl alcohol (PVA) membrane material is used as an example for illustration. However, the method disclosed herein is not limited to the fiberization of polyvinyl alcohol membrane materials, but may also be applied to the fiberization of other polymer membranes or suitable materials.

[0013] Polyvinyl alcohol film materials can be obtained by saponifying polyvinyl acetate resin. Examples of polyvinyl acetate resins include monopolymers of vinyl acetate, i.e., polyvinyl acetate, copolymers of vinyl acetate, and other monomers that can copolymerize with vinyl acetate. Examples of other monomers that can copolymerize with vinyl acetate include unsaturated carboxylic acids (e.g., acrylic acid, methacrylic acid, ethyl acrylate, propyl acrylate, methyl methacrylate), olefins (e.g., ethylene, propylene, 1-butene, 2-methylpropene), vinyl ethers (e.g., ethyl vinyl ether, methyl vinyl ether, n-propyl vinyl ether, isopropyl vinyl ether), and unsaturated sulfonic acids (e.g., vinyl sulfonic acid, sodium vinyl sulfonate).

[0014] Referring to step 21 of FIG2, taking a polyvinyl alcohol (PVA) membrane as an example, the modification treatment 21 includes, for example, a swelling process 22, a bridging process 23, and / or a stretching process 24. As shown in FIG2, in some embodiments, the PVA membrane can be passed through multiple continuously arranged process baths, including, for example, a swelling bath, a bridging bath, and / or a stretching bath, to swell, bridge, and / or stretch the PVA membrane, thereby modifying the membrane of the embodiment. In one embodiment, the above-mentioned swelling, bridging, and stretching processes can be selectively performed in one or more combinations.

[0015] In the above swelling process 22, the polyvinyl alcohol film material driven by the roller is first immersed in the swelling bath (the swelling liquid is water) and swells. This step is beneficial to the polyvinyl alcohol film material having better extensibility in the subsequent stretching process 24.

[0016] In the above-mentioned bridging process 23, the bridging bath contains, for example, an aqueous solution of boric acid. Immersing the polyvinyl alcohol membrane in boric acid can provide bridging between polyvinyl alcohol polymer chains, thereby increasing the weather resistance and physical and mechanical properties of the polyvinyl alcohol membrane.

[0017] In the above-described stretching process 24, the length of the polyvinyl alcohol film can be stretched in the stretching bath to, for example, 0.5 to 7 times, more preferably 2 to 7 times, and even more preferably 4 to 7 times, the original length. The above-described stretching process 24 can be uniaxial or biaxial stretching. In the example of biaxial stretching, the stretching multiple of the polyvinyl alcohol film in the length direction is greater than the stretching multiple in the width direction. The stretching process 24 can increase the area of ​​the polyvinyl alcohol film and improve its mechanical strength.

[0018] In one embodiment, the number of the above-mentioned swelling bath, bridging bath and extension bath can be increased or decreased as needed.

[0019] Furthermore, in some embodiments, the extended polyvinyl alcohol (PVA) membrane can be immersed in a potassium hydroxide (KOH) bath (not shown), for example, about 1%-10% KOH for several seconds (e.g., 10 seconds), which can improve the tensile strength of the material itself, making the PVA membrane easier to break into fibers in subsequent steps, and also further improving the strength of the fiber product. Afterwards, the PVA membrane removed from the KOH bath is washed with water to remove the KOH from its surface. Then, a drying process is performed to remove excess moisture from the PVA membrane, making it easier to break into fibers in subsequent steps, and also further improving the strength of the fiber product. In some embodiments, the moisture content of the PVA membrane is controlled at about 2-10%.

[0020] Subsequently, referring to step 12 of FIG1 and membrane patterning 25 of FIG2, the membrane material is patterned, for example, by recessing the membrane material to form a plurality of recesses, according to some embodiments. In some embodiments, these recesses are arranged substantially parallel to each other, and adjacent recesses are spaced apart by a distance. The size of this distance (i.e., the length L1 of the protrusion 34, detailed later) depends on the length of the fiber to be formed. The methods of patterning the membrane material and the details of forming the recesses in some embodiments will be detailed later.

[0021] Next, referring to the film winding 27 in FIG2, the patterned film material is wound up according to some embodiments. After the film material forms multiple recesses, a portion of the film material remains below the recesses without breaking, thus remaining a continuous film material that can be wound up. The wound film material has advantages such as small volume, easy storage, and easy transport. Furthermore, the patterned film material at this time does not yet limit the width of the subsequently produced fiber. The width of the produced fiber can be freely adjusted in the subsequent fiberization process according to the width required for the actual application.

[0022] Subsequently, referring to step 13 of FIG1 and the membrane material rupture into fibers 29 of FIG2, according to some embodiments, an external force is applied to rupture the membrane material to form a plurality of fiber elements having a predetermined size. This step may also be referred to herein as a membrane material fiberization step (or fiberization process). In some embodiments, a roller-type external force device, such as a rolling device without blades, may be provided to apply pressure to the membrane material to rupture it into a plurality of fiber elements. In this fiberization step, the recesses previously created on the membrane material provide the break point region when the membrane material ruptures. Details of the membrane material fiberization steps of some embodiments and related equipment that can be used to rupture the membrane material will be described in detail below.

[0023] Then, referring to step 14 of FIG1, according to some embodiments, the fiber pieces formed after the membrane material is ruptured are collected.

[0024] It is worth noting that when actually applying the membrane fiberization method 10 of the present disclosure embodiment, it is not necessary to perform all steps continuously. Alternatively, after completing the patterning step of the membrane material (step 12), it can be wound up and stored first. When it is necessary to obtain the fiber part later, the rolled membrane material with the concave portion is supplied to the relevant equipment (e.g., a rolling equipment) to break the membrane material (step 13).

[0025] Figures 3A, 4A, and 5A show top views of an intermediate stage of a membrane fiberization method according to some embodiments of the present invention. Figures 3B, 4B, and 5B show cross-sectional views of an intermediate stage of a membrane fiberization method according to some embodiments of the present invention. Figures 3B, 4B, and 5B are cross-sectional views of Figures 3A, 4A, and 5A, respectively.

[0026] Referring to Figures 3A and 3B, a membrane material 31 is provided according to some embodiments. This membrane material is, for example, a continuous membrane material that has undergone the above-described modification treatment 21 (e.g., the swelling process 22, bridging process 23, and / or stretching process 24 of Figure 2). In some embodiments, the membrane material 31 has a generally flat upper surface 311 and a lower surface 312. The membrane material 31 has a generally uniform thickness T.

[0027] Referring to Figures 4A and 4B, according to some embodiments, the membrane material 31 is patterned to recess the membrane material 31 from its upper surface 311, thereby forming an uneven structure (e.g., recesses 32 and protrusions 34) on the membrane material surface. As shown in Figure 4A, the formed recesses 32 are spaced apart in a first direction D1 and extend in a second direction D2, which is different from the first direction D1. The second direction D2 forms an angle with the first direction D1. In a non-limiting example, the second direction D2 is substantially perpendicular to the first direction D1. Furthermore, in some embodiments, the first direction D1 is substantially parallel to the machine direction (MD) of the membrane material 31, such as the stretching direction of the membrane material 31.

[0028] As shown in FIG4B, after the film material 31 is patterned, a protrusion 34 is formed between two adjacent recesses 32. The formed recesses 32 do not cut through the film material 31, but leave a portion of the film material connecting the adjacent protrusions 34. Therefore, according to some embodiments, the patterned film material 31 includes a continuous substrate 33 and a plurality of protrusions 34 located on the continuous substrate 33, with recesses 32 between the protrusions 34. The upper surface 341 of the protrusions 34 is higher than the upper surface 331 of the continuous substrate 33 exposed at the recesses 32.

[0029] In some embodiments, the membrane 31, the recess 32, and the continuous substrate 33 each have a thickness T, a depth t1, and a thickness t2 in a third direction D3, respectively, wherein the thickness T is the sum of the depth t1 and the thickness t2 (T = t1 + t2). In some embodiments, the depth t1 of the recess 32 is approximately equal to the height of the protrusion 34 protruding above the continuous substrate 33. Since the recess 32 does not cut through the membrane 31, the depth t1 of the recess 32 is less than the thickness T of the membrane 31 (t1 < T).

[0030] The depth t1 of the recess 32 should not be too shallow, otherwise it will be difficult to apply external force to make the membrane material fibrous. The depth t1 of the recess 32 should also not be too deep, otherwise it will be easy to break the continuous bottom layer 33, and it will also be difficult to wind up. In some embodiments, the membrane material 31 has a thickness T, and the recess 32 has a depth t1 (T and t1 have the same unit). When the depth t1 and the thickness T satisfy the following formula (1), the membrane material 31 can be wound up smoothly and is a continuous roll without breakage:

[0031] 0.31 ≤≤ 0.95……………….(1).

[0032] Furthermore, although in this example cross-section, the protrusion 34 has a generally flat upper surface 341 and the continuous underlayer 33 has a generally flat upper surface 331, this disclosure is not limited thereto. The protrusion 34 may have a convex, concave, or other non-flat upper surface 341, depending on the surface shape of the fiber piece to be formed subsequently. The continuous underlayer 33 may also have a convex, concave, or other non-flat upper surface 331, and this disclosure is not particularly limiting. Any cross-sectional shape that allows the continuous underlayer 33 to be broken in the subsequent breaking step of the embodiment is within the scope of this disclosure.

[0033] Furthermore, in some embodiments, protrusions 34 are provided between adjacent recesses 32. That is, the distance between adjacent recesses 32 in the first direction D1 is the length L1 of the protrusions 34. The lengths L1 of each protrusion 34 in the first direction D1 may be the same or different. In practical applications, the length L1 of the protrusions 34 (the distance between recesses 32) depends on the length of the fiber piece to be formed subsequently.

[0034] Furthermore, in some embodiments, adjacent protrusions 34 have a distance P1 in the first direction D1. That is, the distance between adjacent protrusions 34 in the first direction D1 is the length of the recess 32 in the first direction D1 (= distance P1). The distances P1 between adjacent protrusions 34 can be the same or different, and can be configured appropriately according to the actual application. If the distance P1 is too large, it will cause unnecessary waste of materials. In some embodiments, the distance P1 is less than the length L1.

[0035] Referring then to Figures 5A and 5B, according to some embodiments, an external force is applied to rupture the membrane material 31 to form a plurality of fiber elements. For example, pressure can be applied to the membrane material 31 by a rolling mill to rupture the membrane material into a plurality of fiber elements. In some embodiments, the extending direction of the recess 32 is substantially perpendicular to the conveying direction of the membrane material 31 to the rolling mill (the two directions are approximately at a 90-degree angle). For example, the membrane material 31 is conveyed along a first direction D1 to between the pressure rollers of the rolling mill, the axial direction of the pressure rollers being arranged, for example, along a second direction D2. Protrusions disposed on the pressure rollers and the pressure applied to the membrane material 31 cause the membrane material 31 to break at the recess 32, rupturing into a plurality of fiber elements FP, each fiber element FP including an elongated protrusion 34 (Figures 4A and 4B). Each fiber element FP has a width W in the second direction D2.

[0036] Therefore, according to some embodiments of this disclosure, the length of each fiber element in the first direction D1 can be controlled by forming the recesses 32. The greater the distance between adjacent recesses 32, the longer the length of each fiber element in the first direction D1. The pressure of the rollers of the rolling mill on the protrusions 34 of the film material 31 can simultaneously destroy the recesses 32 at both ends of each protrusion 34, causing it to break into fiber elements FP that are separated from each other in the second direction D2. Therefore, according to the method proposed in the embodiments, multiple fiber elements FP with predetermined dimensions can be produced.

[0037] It is worth noting that, according to some embodiments, the continuous underlayer 33 portion at each recess 32 serves as the breakage point region when the membrane material ruptures. In order to clearly show the separated fiber element FP in the top view, only the protrusion 34 is shown in FIG. 5A, while the broken portion of the continuous underlayer 33 connecting the bottom ends of the protrusion 34 is omitted. FIG. 5B clearly shows that the broken portion of the continuous underlayer 33 remains at the bottom ends of a single protrusion 34. The vertical chain lines in FIG. 5B are used to indicate each breakage point.

[0038] The following are some examples illustrating some related devices that can be applied to patterned films (operations as shown in Figures 4A and 4B) and fractured films (operations as shown in Figures 5A and 5B). However, the following description is only the content of some embodiments, and this disclosure is not limited to these illustrated devices and related operating instructions.

[0039] According to some embodiments, the film material 31 may undergo an embossing process, a cutting process, or other suitable methods to form the recess 32 shown in Figures 4A-4B. Figure 6 shows a schematic diagram of an embossing process performed on the film material using an embossing device according to some embodiments of the present invention. In some embodiments, an embossing device 4 is used to emboss the extended film material 31.

[0040] In some embodiments, the embossing equipment may include a rectangular jig (not shown) or a jig of other shapes to perform an embossing process on the film material 31.

[0041] In some embodiments, the embossing apparatus 4 includes an embossing wheel 40 and a plurality of rollers 43a-43d. The embossing wheel 40 is disposed above the film material 31. The embossing wheel 40 includes a wheel body 41 and a plurality of protrusions 42 on the surface of the wheel body 41. The film material 31 is conveyed via the rollers 43a and 43b of the conveying section and is guided onto the embossing wheel 40, which has a concave-convex shape opposite to the concave-convex structure to be formed on the film material 31. The positions of the protrusions 42 on the surface of the wheel body 41, the conveying speed of the film material 31, and the rotational speed of the embossing wheel 40 are adjusted in coordination to form the desired concave-convex shape on the surface of the film material 31. As shown in FIG6, when the film material 31 is subjected to the embossing process, the film material 31 is sandwiched between the embossing wheel 40 and the rollers 43c, and these protrusions 42 contact and press down on the surface of the film material 31 (e.g., the upper surface 311), thereby forming concave portions 32 on the surface of the film material 31. The patterned film 31 is conveyed via roller 43d for the next operation.

[0042] The embossing pattern can be of any shape, depending on the desired shape of the recess 32. Furthermore, the embossing can be controlled by temperature to achieve the required depth of the recess 32 (e.g., depth t1) in the film material 31. In some embodiments, the embossing process is performed, for example, within a melt processing temperature range of the film material 31. Taking a thermoplastic polymer film as an example, mechanical embossing at a temperature that melts the polymer film softens it and makes it easier to shape, thus forming an uneven structure on the surface of the polymer film. If the embossing temperature is set too low, it may be difficult to form an uneven structure on the surface of the film material 31. If the embossing temperature is set too high (e.g., exceeding 90°C) or the film material 31 is pressed for too long, the surface of the film material 31 may undergo a qualitative change.

[0043] In some embodiments where a polyvinyl alcohol (PVA) film is used as the film material 31, the embossing temperature is set between approximately 40°C and approximately 90°C, or between approximately 50°C and approximately 80°C, or between approximately 55°C and approximately 70°C, or other suitable temperature ranges, so that the PVA is in a molten state and easily shaped. If the embossing temperature exceeds approximately 90°C, the surface of the PVA may undergo a qualitative change, such as the formation of polyene polymers and yellowing. The embossed film material 31 is conveyed at room temperature and cooled and shaped to obtain the desired textured structure.

[0044] Therefore, according to the above, the temperature of the embossing process can be determined according to the actual selected film material 31, and the temperature range that allows the film material 31 to be melted and processed without causing the film material 31 to undergo qualitative changes is preferred.

[0045] Furthermore, the pattern of the embossing fixture used in the embossing process, such as the protrusions 42 on the embossing wheel, complements the shape of the recesses 32 of the film material 31, thereby affecting the cross-sectional shape of the final fibrous product. Therefore, according to some embodiments, the embossing fixture can be provided with protrusions 42 of a specific shape and the spacing of the protrusions 42 can be configured according to the shape requirements of the fibrous product.

[0046] In some embodiments, the shape of the protrusion 42 may be arc-shaped, triangular, quadrilateral, or polygonal, for example, pentagonal or hexagonal. Furthermore, the shape of the protrusion 42 of the present invention may also be a combination of the above-mentioned shapes.

[0047] In addition, during the embossing process, the softness of the membrane surface can be improved in other ways to facilitate the shaping of the membrane. Figure 7 shows a schematic diagram of an embossing wheel according to some embodiments of the present invention. In some embodiments, the embossing wheel 40 includes a wheel body 41 and a plurality of protrusions 42 on the surface of the wheel body 41. In some embodiments, one or more protrusions 42 further include holes 423 as water outlets. When the protrusions 42 contact the surface of the membrane 31, water can exit through the holes 423 to wet the surface of the membrane 31, thereby improving the softness of the membrane 31 and making it easier for the surface of the membrane 31 to form concave portions 32 due to the pressure of the protrusions 42, thus improving the embossing effect.

[0048] Although one protrusion 42 in Figure 7 includes one water outlet 423, this disclosure does not limit the number and size of the water outlets 423. For example, a protrusion 42 may include multiple water outlets of suitable size distributed on the surface of the protrusion 42, so that water can be discharged simultaneously when the protrusion 42 contacts the surface of the membrane material 31 to wet the surface of the membrane material 31. Therefore, the surface of the membrane material 31 under the embossing wheel 40 can have good softness due to the swelling of water, which is beneficial for the protrusion 42 to shape the surface of the membrane material 31. Furthermore, in addition to the above-mentioned water outlet method, other suitable methods can also be used, such as providing other components on the membrane material 31, such as a shower head, sprayer or humidifier (not shown), to supply additional water and humidity, so as to swell the surface of the membrane material 31 and improve the embossing effect.

[0049] In addition to the above-mentioned embossing process, non-blade cutting equipment, such as laser cutting, water jet cutting or other suitable cutting equipment, can be used to cut the film material 31 to form the recess 32 as shown in Figures 4A-4B.

[0050] FIG8 shows a schematic diagram of a laser cutting apparatus according to some embodiments of the present invention. A laser beam 52 emitted by the laser cutting apparatus 51 impacts the surface of a film 31, for example, the laser beam 52 impacts from the upper surface 311 of the film 31 toward the thickness direction of the film 31 to remove a portion of the film 31, and the laser beam 52 extends along a predetermined path (e.g., along a second direction D2) on the surface of the film 31 to form a recess 32 with a predetermined depth (as shown in FIG4A and FIG4B). By adjusting the intensity of the laser beam 52 and the time for damaging the surface of the film 31, and by gradually moving the film 31, a plurality of recesses 32 with appropriate spacing are formed on the surface of the film 31.

[0051] Furthermore, in some embodiments, after patterning the membrane material 31 (as shown in step 12 of FIG. 1) and before fiberizing the patterned membrane material 31 (as shown in step 13 of FIG. 1), a step of detecting the moisture content of the patterned membrane material 31 may be included. In some embodiments, if the moisture content of the patterned membrane material exceeds 10%, a drying process may be performed to give the patterned membrane material a moisture content in the range of about 2% to about 10%, followed by a fiberizing step in which external force is applied to break the patterned membrane material into multiple fiber pieces. The drying process can remove moisture from the material, control the moisture content of the membrane material to 2-10%, make the material easier to break into fibers, and also improve the strength of the fiber product. If the moisture content of the patterned membrane material is in the range of about 2% to about 10%, the fiberizing step may continue to produce multiple fiber pieces.

[0052] According to some embodiments, after patterning the membrane material 31, such as by embossing, non-blade cutting (laser or waterjet cutting), or any other suitable process that can form recesses 32 on the surface of the membrane material 31, the patterned membrane material 31 can be subjected to a fiberization operation to break the membrane material and form a plurality of fiber elements FP (as shown in Figures 5A and 5B). The following description of the equipment and operations is for illustrative purposes only and this disclosure is not limited to the illustrated equipment and related operational descriptions.

[0053] Figure 9 shows a schematic diagram of membrane fiberization according to some embodiments of the present invention. In some embodiments, a roller-type external force device or other external force breaking device may be used to fiberize the membrane 31. For example, an external force may be applied to the patterned membrane (the surface of the membrane 31 has recesses 32) by means of a rolling device 6 without blades, an irregular press, or any suitable device to break the membrane.

[0054] As shown in FIG. 9, a roll of patterned film material 31 is provided, and one end of the film material 31 is fed between the lower pressure roller 61 and the upper pressure roller 62 of the rolling equipment 6. The lower pressure roller 61 and the upper pressure roller 62 apply pressure to the film material 31, causing the film material 31 to break into a plurality of fiber pieces FP with predetermined sizes. Furthermore, a container (e.g., a bag or box) 65 is provided below the pressure rollers to collect these fiber pieces FP.

[0055] Figure 10 shows a partial schematic diagram of a single pressure roller in a rolling apparatus according to some embodiments of the present invention. Figure 10 uses the lower pressure roller 61 in Figure 9 as an example. The lower pressure roller 61 is equipped with multiple adjustable components, which can be set to be raised or flat according to the required dimensions. The upper pressure roller 62 also has similar adjustable components. These adjustable components can be set according to the width of the fiber to be formed, thus allowing for rapid adjustment of the position of the pressure application point when the fibrous membrane 31 is formed, depending on the application requirements.

[0056] In some examples, as shown in FIG10, a portion of the lower pressure roller 61 includes adjusting members 61-1, 61-2, and 61-3. Adjusting members 61-1 and 61-3 are configured to be raised, while adjusting member 61-2 is configured to be flat. When the lower pressure roller 61 breaks the patterned film material 31, adjusting members 61-1 and 61-3, as protrusions of the lower pressure roller 61, contact the lower surface of the film material 31. FIG10 shows only three adjusting members, but the actual pressure roller includes more adjusting members sequentially arranged on the roller surface, and the raised or flat state of each adjusting member can be set according to the width of the fiber to be formed.

[0057] Figures 11A and 11B show schematic diagrams of a fibrous film material processed by a rolling mill according to some embodiments of the present invention. In some embodiments, the rolling mill includes a lower pressure roller 61 and an upper pressure roller 62. The lower pressure roller 61 includes a plurality of adjusting members, and the adjusting members 61-1, 61-3, 61-5, 61-7, 61-9, and 61-11 are configured as protrusions to act as protrusions of the lower pressure roller 61, which can contact the lower surface of the patterned film material 31. The upper pressure roller 62 also includes a plurality of adjusting members, and the adjusting members 62-1, 62-3, 62-5, 62-7, 62-9, and 62-11 are configured as protrusions to act as protrusions of the upper pressure roller 62, which can contact the upper surface of the patterned film material 31. The protrusions of the lower pressure roller 61 and the upper pressure roller 62 are staggered.

[0058] Referring to FIG11A, when the patterned film material 31 (having a recess 32 extending along the second direction D2) is supplied along the first direction D1 between the lower pressure roller 61 and the upper pressure roller 62, the arrangement of the protrusions of the upper pressure roller 62 determines the width of the fiber piece formed after crushing the film material 31. For example, the distance between the adjusting member 61-1 of the lower pressure roller 61 and the adjusting member 62-1 of the upper pressure roller 62 in the second direction D2 corresponds to the width WA of the crushed fiber piece. The length L2 of the protrusion 34 between the recesses 32 in the first direction D1 corresponds approximately to the length of the fiber piece.

[0059] Figure 11B is similar to Figure 11A, the main difference being the distance between the adjusting members. Referring to Figure 11B, the lower pressure roller 61 includes multiple adjusting members, and adjusting members 61-3, 61-7, and 61-11 are set as protrusions to serve as protrusions of the lower pressure roller 61, which can contact the lower surface of the patterned film material 31. The upper pressure roller 62 also includes multiple adjusting members, and adjusting members 62-1, 62-5, and 62-9 are set as protrusions to serve as protrusions of the upper pressure roller 62, which can contact the upper surface of the patterned film material 31. The protrusions of the lower pressure roller 61 and the upper pressure roller 62 are staggered. When the patterned film 31 (with a recess 32 extending along the second direction D2) is supplied along the first direction D1 between the lower pressure roller 61 and the upper pressure roller 62, the arrangement of the upper pressure roller 62 and the protrusions of the upper pressure roller 62 determines the width WB of the fiber formed after crushing the film 31, wherein the width WB is greater than the width WA.

[0060] The aforementioned rolling device 6 or similar external force breaking device can cause the membrane material 31 to break with only simple external force. Since no blade is required, it offers high safety during the fiberization process. However, this disclosure is not limited to this. In some other embodiments, a blade-type cutting machine can be used to cut between the recesses 32 of the membrane material 31, with the cutting direction forming an angle greater than 0 degrees with the extending direction of the recesses 32 (e.g., a second direction), thereby forming multiple fiber pieces FP. In some embodiments, the cutting direction is, for example, perpendicular to the extending direction of the recesses 32.

[0061] According to the method proposed in the above embodiments, a fiber product comprising multiple fiber elements FP having the required size can be quickly produced from a membrane material (e.g., a polymer membrane). As proposed in the above embodiments, when the patterned membrane material is broken by an external force (e.g., a rolling device), the recesses 32 provide breakage areas. Therefore, each fiber element FP, in addition to the protrusions 34 between the recesses 32 (Figures 4A and 4B), also includes a continuous underlayer 33 at a portion of the recesses 32. This continuous underlayer 33 is an extension of at least one or both ends of the main body of each fiber element FP.

[0062] FIG12 shows a schematic diagram of a single fiber member manufactured by a method according to some embodiments of the present invention. Each fiber member FP includes a main body 71 and two extensions 72, 73 disposed at both ends of the main body 71. The lower surface 712 of the main body 71. The upper surface 711 of the main body 71 is higher than the upper surfaces 721, 731 of the extensions 72, 73. In some embodiments, the first direction D1 is the film material machining direction, such as the film material stretching direction, and the extensions 72, 73 are disposed at both ends of the main body 71 along the machining direction.

[0063] Furthermore, the main body 71 and the extensions 72 and 73 have lengths L1, L12, and L13 respectively in the first direction D1. Therefore, the total length L of the fiber member FP in the first direction D1 is the sum of lengths L1, L12, and L13. If, according to the design requirements, the length of the protrusion 34 (Fig. 4A, Fig. 4B) of the patterned film material in the first direction D1 has a high ratio to the length of the recess 32 in the first direction D1, then the total length L of the fiber member FP is approximately the same as the length L1 of the main body 71.

[0064] Furthermore, if the patterned film is broken using a non-blade cutting method (e.g., a rolling mill), it is possible for the continuous bottom layer 33 at the recess 32 to break at any point. Therefore, the distances from the break points on both sides of the main body 71 to the main body 71 may be approximately the same or significantly different. That is, in some embodiments, the lengths of the two extensions 72, 73 of a single fiber piece FP may be approximately the same or different. Alternatively, in some embodiments, the length of one of the extensions of a single fiber piece FP is very short, and the fiber piece FP can be considered as having only one extension.

[0065] In some embodiments, the length of each fiber FP formed is greater than or equal to the distance between two adjacent recesses 32 in the first direction D1 (= the length L1 of the protrusion 34 in FIG4B), and less than or equal to the sum of this distance and twice the length of the recess in the first direction D1 (= the distance P1 of the protrusion 34).

[0066] Based on the above, compared with the existing fiber manufacturing methods, such as wet spinning, dry spinning or melt spinning, the fiber manufacturing method proposed in the embodiment is simpler, has lower chemical cost and less waste liquid, does not require high-temperature process, and has the advantages of energy saving, environmental protection and low cost.

[0067] Taking the production of polyvinyl alcohol fiber parts by wet spinning as an example, the main process involves using polyvinyl alcohol as raw material, adding some composite crosslinking agents, such as a composite crosslinking agent composed of zirconium, boron, titanium, and silicon. After dissolving in water, the fiber passes through multiple process baths, including spinning in a first coagulation bath, dehydration and coagulation in a second coagulation bath, wet hot drawing in a bath, decrosslinking treatment in an acid bath, and removal of acid and sodium sulfate from the fiber in a neutralization bath. Afterward, the fiber undergoes drying treatment, and finally, dry hot drawing is performed to achieve a total draw ratio of 15 to 18 times. Therefore, the wet spinning process is complex (requiring equipment such as first and second coagulation baths, drawing tanks, acid tanks, neutralization tanks, drying and hot drawing), and the cost of the chemical solutions is high, generating a large amount of waste liquid (including zirconium compounds, titanium salts, borates, silicates, sodium hydroxide, sodium sulfate, sulfuric acid, etc.), and the process temperature is high (e.g., the hot drawing temperature is about 225℃ to 245℃).

[0068] Taking dry spinning to produce fiber parts as an example, after the polymer is dissolved in a solvent, the process from the melting point to the spinning process is the same as that of wet spinning. However, instead of using a coagulating liquid, the spinning fluid is directly injected into hot air to evaporate the solvent and solidify the fiber, similar to injection molding spinning methods. In short, dry spinning involves heating the raw material and then drawing it into fibers through contact with hot and cold air.

[0069] Taking melt spinning to produce fiber parts as an example, after the polymer is polymerized into ester particles, it is melted at high temperature and extruded through the spinning nozzle by precision extrusion rollers and precision pumps. Then, dozens or hundreds of polymer fibers fall down by gravity and are wound up by several extension rollers to control the fiber fineness.

[0070] Therefore, the current fiber component manufacturing method involves very complex steps, requires a high-temperature process, consumes a lot of energy, has high chemical costs, and generates a large amount of waste liquid. The fiber component manufacturing method proposed in this embodiment has a simpler process, lower chemical costs (e.g., using boric acid, sulfuric acid, potassium sulfate) and is easy to recycle and reuse, generates less waste liquid, and does not require a high-temperature process (drying oven temperature ≤100°C). Therefore, this embodiment has the advantages of energy saving, environmental protection, and low production costs.

[0071] In one embodiment, the fiber FP can be further cut, ground or crushed to meet the requirements of subsequent product applications.

[0072] <Application of Fiber Products>

[0073] In some applications, the fiber products of the embodiments (such as the plurality of fiber parts FP described above) can be mixed into building materials, such as cement, concrete raw materials or asphalt concrete, to improve their properties.

[0074] In detail, cement raw materials include calcium oxide (CaO). Taking Portland cement clinker as an example, it is mainly composed of four oxides: calcium oxide (CaO), silicon oxide (SiO2), aluminum oxide (Al2O3), and iron oxide (Fe2O3). These four oxides typically account for more than 95% of the total clinker, with the remaining 5% or less consisting of minor oxides, magnesium oxide (MgO), sulfur trioxide (SO3), titanium oxide (TiO2), phosphorus oxide (P2O5), and salts (K2O, Na2O), etc. With increasingly stringent building regulations and more complex modern construction methods, the requirements for cement strength are becoming increasingly higher. Incorporating the fiber component FP from the embodiment into the cement can improve the mechanical properties of the cement and increase the strength of the building. In concrete applications (including mixtures of modified cement, stone (coarse aggregate), sand (fine aggregate), and water), concrete made with cement incorporating the fiber component FP from the embodiments exhibits a denser surface and improved weather resistance. Furthermore, in some applications, the fiber products from the embodiments (such as the aforementioned fiber components FP) can be incorporated into asphalt concrete for road paving to increase road strength and improve the coefficient of friction.

[0075] [Related Experiments and Evaluations]

[0076] Please refer to Figures 4A, 4B, 5A, 5B and the above description simultaneously. This disclosure also addresses the influence of embossing temperature on the film material during patterning processes such as embossing in some embodiments, including whether embossing can be completed and whether the film material undergoes a qualitative change. Furthermore, this disclosure also addresses the relevant dimensions of the patterned film material (e.g., film thickness T, depth t1 of the recesses, spacing P1 of the protrusions 34, and length L1 of the protrusions 34) and winding evaluation, including whether the patterned film material can be wound smoothly and whether the patterned film material breaks during winding.

[0077] The following are experiments and evaluations of patterning and fiberization processes for modified polyvinyl alcohol films. However, the following experimental results are for illustrative purposes only and should not be construed as limiting the implementation of this disclosure.

[0078] Furthermore, the membrane patterning process (e.g., embossing process or laser cutting process) and fiberization process proposed in the experimental examples are briefly described below, along with their related equipment and evaluation methods. Detailed process descriptions can also be found in the above embodiments. The processes and evaluation methods will not be repeated in subsequent analyses.

[0079] <Membrane Material Patterning Process>

[0080] (A) Embossing process

[0081] The modified polyvinyl alcohol film is embossed using a jig.

[0082] Jig dimensions: Rectangular 150mm * 0.1mm. The embossing temperature is adjusted accordingly based on the settings of each experimental example.

[0083] (B) Cutting process

[0084] The modified polyvinyl alcohol film can also be laser-cut to the required depth. Furthermore, the depth of the recess formed by the cutting can be measured using a laser microscope.

[0085] <Fiberization Process>

[0086] The patterned polyvinyl alcohol film is pressed and cut using a rolling device as shown in Figure 11A or Figure 11B, and it is confirmed whether it can be broken.

[0087] The pressing tube diameter of the upper and lower pressure rollers of the rolling equipment used in the experiment is about 5cm, and the adjusting parts of the upper and lower pressure rollers are long strips with a spacing of about 0.2cm. Therefore, the width of the fiber piece is about 0.2cm.

[0088] <Evaluation Items>

[0089] (1) Whether it can be pressed into flowers:

[0090] Observe the appearance of the membrane material to see if there are embossed patterns on the surface. The depth of the recess after pressing can also be measured with a microscope. Table 1 lists the membrane material thickness T, the depth of the recess t1, the spacing P1 of the protrusions 34, and the length L1 of the protrusions 34 (refer to Figure 4B).

[0091] (2) Whether it can be collected:

[0092] A small tube was used to conduct a winding test on the patterned membrane material, and the appearance of the membrane material was observed to confirm its winding feasibility. The winding diameter of the small tube was about 5 cm, and the winding speed was about 1 meter / minute.

[0093] (3) Whether it is fracture-resistant:

[0094] As described in the fiberization process, after the patterned polyvinyl alcohol film is pressed and cut using a rolling equipment, the appearance is observed and it is confirmed whether it can be successfully broken into multiple separate fiber parts.

[0095] (4) Whether a qualitative change has occurred:

[0096] Confirm whether the patterned polyvinyl alcohol film has undergone a qualitative change, such as yellowing. If the temperature used in the patterning process is too high, the polyvinyl alcohol film will form polyene polymers and yellow.

[0097] Table 1 lists the evaluation of film materials subjected to different embossing temperatures during the embossing process.

[0098] In the items in Table 1, "○" indicates that the membrane surface is successfully embossed with patterns, can be smoothly rolled up, and can be broken into multiple fiber parts; "╳" indicates that the membrane surface cannot be smoothly embossed and cannot be broken.

[0099] It is worth noting that in Table 1, “╳” indicates that the mold material has not undergone a qualitative change.

[0100] Table 1 Pressing temperature Membrane thickness T (µm) concavity Depth t1 (µm) Protrusion spacing P1 (mm) Length L1 of the protrusion (mm) Can it be pressed into flowers? Can the roll be collected? Is it breakable? Has a qualitative change occurred? 35℃ 20.3 16 0.1 5 ╳ ○ ╳ ╳ 0.888 40℃ 19.3 15.5 0.1 5 ○ ○ ○ ╳ 0.896 90℃ 20.1 15.8 0.1 5 ○ ○ ○ ╳ 0.887 95℃ 19.9 16 0.1 5 ○ ○ ○ A qualitative change occurred 0.897

[0101] According to the results in Table 1, in some experimental examples, polyvinyl alcohol (PVA) films can be successfully patterned (e.g., embossed) at temperatures between approximately 40°C and approximately 90°C, and can be smoothly wound up and broken into multiple fiber components. Furthermore, the PVA film does not undergo any qualitative change (no yellowing occurs). If the patterning temperature is too low, for example, an embossing temperature of approximately 35°C, patterning cannot be successfully performed on the surface of the PVA film. If the patterning temperature is too high, for example, an embossing temperature of approximately 95°C, the surface of the PVA film will undergo qualitative change (yellowing occurs).

[0102] It is worth noting that Table 1 only lists some of the experimental results. Multiple patterning experiments were also conducted at other temperatures between 40°C and 90°C, which also successfully patterned the polyvinyl alcohol film (e.g., embossed it), and it could be smoothly wound and broken into multiple fiber components. Furthermore, the polyvinyl alcohol film did not undergo any qualitative changes (no yellowing occurred). These are omitted here.

[0103] Table 2 lists the relevant dimensions of the patterned membrane material, as well as the relevant evaluations on whether it can be rolled up and whether it can be fiberized. Among them, "○" indicates that the pattern has been successfully embossed on the surface of the membrane material.

[0104] Table 2 Membrane thickness Membrane thickness T (µm) Concave depth t1 (µm) Protrusion spacing P1 (mm) Length L1 of the protrusion (mm) Can it be pressed into flowers? Can the roll be collected? Is it breakable? thick 20.3 18.8 0.1 5 ○ It cannot be rolled up and is easily torn. Can break 0.962 Thin 15.6 14.5 0.1 5 ○ It cannot be rolled up and is easily torn. Can break 0.964 thick 21.6 19.5 0.1 5 ○ Retractable Can break 0.950 Thin 15.3 13.9 0.1 5 ○ Retractable Can break 0.953 thick 21.1 2.1 0.1 5 ○ Retractable Can break 0.315 Thin 15.3 1.6 0.1 5 ○ Retractable Can break 0.323 thick 21.6 1.9 0.1 5 ○ Retractable 95% unbreakable 0.297 Thin 14.7 1.4 0.1 5 ○ Retractable 93% unbreakable 0.309

[0105] Please also refer to Figure 4B. According to the results in Table 2, when the depth t1 of the recess 32 and the thickness T of the membrane 31 satisfy equation (1),

[0106] 0.31 ≤≤ 0.95……………….(1),

[0107] The patterned film material can be smoothly wound up (i.e., a continuous roll without breakage). And in the subsequent fiberization process, it can be successfully broken into multiple fiber components.

[0108] In summary, compared to the current fiber manufacturing processes (such as the aforementioned wet spinning or dry spinning), which are complex, energy-intensive, have high-temperature processing costs, high chemical costs, and generate large amounts of waste liquid, the fiber manufacturing method proposed in this embodiment can break down fiber parts into the required size by providing a membrane material and patterning and fiberizing the membrane material. The provided membrane material can be a modified membrane material to enhance its properties. Taking polyvinyl alcohol fiber parts as an example, modified polyvinyl alcohol films that have undergone swelling, cross-linking, and stretching processes can be provided to increase the mechanical strength and water resistance of the resulting fiber parts. The manufacturing method proposed in this embodiment is simple, has low chemical costs, generates little waste liquid, and does not require excessively high-temperature processes, thus offering advantages such as greater energy efficiency, environmental friendliness, and reduced production costs.

[0109] Furthermore, the stacking gaps of the fiber components are large, resulting in a large transport volume. According to some embodiments, after the membrane material is patterned, it can be rolled up first. Rolled membrane materials can save storage space and warehouse storage volume, and shipment in rolls can effectively save transport volume. When the fiber components are needed, the fiberization process described above can be performed (e.g., the patterned membrane material is broken by simple external force).

[0110] Furthermore, after the (modified) membrane material is patterned, for example, the recesses 32 proposed in some of the above embodiments can create breakage points. During the subsequent fiberization process, only simple external force is needed to break the patterned membrane material into fibers of the required width. The distance between adjacent breakage points determines the length of the resulting fiber. Therefore, according to the fiber manufacturing method proposed in the embodiments, the length of the fiber (e.g., by correspondingly changing the position of the breakage points) and / or the width of the fiber (e.g., by correspondingly changing the position of the adjusting element on the pressure roller in a rolling mill) can be adjusted according to the required fiber size, thereby precisely controlling the length and width of the resulting fiber.

[0111] Although this disclosure is based on the foregoing embodiments, it is not intended to limit the scope of this disclosure. Those skilled in the art to which this disclosure pertains can make various modifications and refinements without departing from the spirit and scope of this disclosure. Therefore, the scope of protection of this disclosure shall be determined by the appended claims. Furthermore, each claim constitutes an independent embodiment, and combinations of various claims and embodiments are all within the scope of this disclosure. [Simplified Explanation of the Diagram]

[0112] To make the features and advantages of this disclosure more apparent and understandable, different embodiments are described below in detail with reference to the accompanying drawings. It should be noted that the various features in the drawings are not drawn to scale and are only used for illustrative purposes. In fact, the dimensions of the various elements in the drawings can be arbitrarily enlarged or reduced according to actual applications to clearly demonstrate the features of the embodiments of this disclosure.

[0113] Figure 1 shows a flowchart of a method for fiberizing a membrane material according to some embodiments of the present invention.

[0114] Figure 2 shows a schematic diagram of a membrane fiberization process according to some embodiments of the present invention.

[0115] Figures 3A, 4A, and 5A show top views of an intermediate stage of a membrane fiberization method according to some embodiments of the present invention.

[0116] Figures 3B, 4B, and 5B show cross-sectional schematic diagrams of an intermediate stage of a membrane fiberization method according to some embodiments of the present invention. Figures 3B, 4B, and 5B are cross-sectional schematic diagrams of Figures 3A, 4A, and 5A, respectively.

[0117] Figure 6 shows a schematic diagram of an embossing process for a film material using an embossing device according to some embodiments of the present invention.

[0118] Figure 7 shows a schematic diagram of an embossing wheel according to some embodiments of the present invention.

[0119] Figure 8 shows a schematic diagram of a laser cutting apparatus according to some embodiments of the present invention.

[0120] Figure 9 shows a schematic diagram of membrane fiberization according to some embodiments of the present invention.

[0121] Figure 10 shows a partial schematic diagram of a single pressure roller in a rolling mill according to some embodiments of the present invention.

[0122] Figures 11A and 11B show schematic diagrams of fiberizing a membrane material using a rolling device according to some embodiments of the present invention.

[0123] Figure 12 shows a schematic diagram of a single fiber piece produced by a method according to some embodiments of the present invention.

Claims

1. A method for fiberizing a membrane material, comprising: A membrane material is provided, wherein the membrane material is polyvinyl alcohol. PVA membrane; The membrane material is patterned by recessing it to form a plurality of recesses, which are spaced apart in a first direction; and an external force is applied to rupture the membrane material to form a plurality of fiber members having a predetermined size, wherein the recesses provide a break point region when the membrane material ruptures.

2. The method of fiberizing the membrane material as claimed in claim 1, wherein the recesses extend in a second direction, the second direction being different from the first direction.

3. The method for fiberizing membrane material as claimed in claim 1, wherein after the recesses are formed, the membrane material is a continuous membrane material without breaks, the method further comprising: Rewind the membrane material.

4. The method for fiberizing a membrane material as claimed in claim 3, wherein the membrane material has a thickness, the recesses each have a depth, the thickness is denoted as T, the depth is denoted as t1, and the depth and the thickness satisfy the following formula: 0.31 ≤ ≤ 0.

95.

5. The method for fiberizing the membrane material as claimed in claim 1, wherein the membrane material is subjected to an embossing process or a cutting process to form the recesses.

6. The method for fiberizing a membrane material as claimed in claim 5, wherein an embossing device is used to perform the embossing process on the membrane material, the embossing process being carried out within a melt processing temperature range of the membrane material.

7. The method for fiberizing a membrane material as claimed in claim 6, wherein the embossing equipment includes an embossing wheel, the embossing wheel including a plurality of protrusions, wherein during the embossing process of the membrane material, the protrusions contact and press down on the surface of the membrane material to form the recesses in the membrane material.

8. The method of fiberizing a membrane material as claimed in claim 7, wherein each of the protrusions includes a hole, and when the protrusions contact the surface of the membrane material, water flows out of the hole to wet the surface.

9. The method for fiberizing a membrane material as claimed in claim 5, wherein a non-blade cutting device is used to perform the cutting process on the membrane material.

10. The method for fiberizing a membrane material as claimed in claim 1, wherein a roller-type external force device is provided to apply pressure to the membrane material, causing the membrane material to break into the fiber elements, wherein the roller-type external force device comprises: The upper pressure roller has a first protrusion that contacts the upper surface of the film material; And a lower pressure roller having a second protrusion that contacts the lower surface of the membrane material, wherein the membrane material passes between the upper pressure roller and the lower pressure roller, and the first and second protrusions apply pressure to the membrane material, causing the membrane material to rupture.

11. The method of fiberizing a membrane material as claimed in claim 1, wherein a blade-type cutting machine is provided to apply the external force to the membrane material, and the fiber elements are formed by cutting between the recesses, wherein the cutting direction is at an angle greater than 0 degrees to the extension direction of the recesses.

12. The method for fiberizing a membrane material as claimed in claim 1, wherein the membrane material is modified before being patterned, the modification process including a swelling process, a bridging process or a stretching process.

13. The method for fiberizing the membrane material as claimed in claim 12, wherein after the stretching process, the modification treatment further includes: Immerse the membrane material in 1%-10% potassium hydroxide (KOH); wash the membrane material with water to remove the potassium hydroxide from the membrane material. And dry the membrane material so that its moisture content is in the range of 2%-10%.

14. The method of fiberizing a membrane material as claimed in claim 1, wherein after the recesses are formed in the membrane material and before the external force is applied to cause the membrane material to rupture, the method further comprises: The moisture content of the membrane material is tested. If the moisture content exceeds 10%, a drying step is performed on the membrane material to bring the moisture content to the range of 2%-10%, and then the external force is applied to rupture the membrane material. If the moisture content is within the range of 2%-10%, the step of rupturing the membrane material is continued.

15. The method of fiberizing a membrane material as claimed in claim 1, wherein after the membrane material is ruptured, each of the fiber elements formed has at least one extension located at one end of a main body portion, the length of the extension in the first direction being less than or equal to the length of each of the recesses in the first direction before the membrane material is ruptured.

16. The method for fiberizing a membrane material as claimed in claim 1, wherein the membrane material is patterned at a temperature between 40°C and 90°C to form the recesses in the membrane material.

17. A fiber product comprising a plurality of fiber elements obtained by fiberizing the polyvinyl alcohol film by any one of claims 1 to 16, wherein each fiber element has a main body portion and at least one extension portion located at one end of the main body portion, the upper surface of the main body portion being higher than the upper surface of the extension portion.

18. The fiber product of claim 17, wherein each fiber element has a first extension and a second extension disposed at both ends of the main body along a machining direction, and the length of the first extension is different from the length of the second extension.

19. The fiber product of claim 18, wherein the vertical distance from the upper surface of the main body portion of each fiber element to the upper surface of the extension portion is defined as a depth, and the sum of the depth and the vertical distance between the upper surface of the extension portion and the lower surface of the extension portion is defined as a thickness of each fiber element, wherein the thickness is denoted as T and the depth is denoted as t1, and the depth and the thickness satisfy the following formula: 0.31 ≤ ≤ 0.

95.

20. The fiber product of claim 17, wherein the thickness of the polyvinyl alcohol film is more than 3 μm and less than 100 μm.

21. A building material comprising a fiber product as claimed in any one of claims 17 to 20.

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