Bi-component Fiber Ethylene Polymer Softness Processability
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Solution Overview
Problem
There is a need for bi-component fibers comprising an ethylene-based polymer composition that offers improved processability and enhances the production of non-woven fabrics with improved properties such as softness and drapeability.
Innovation Solution
The development of bi-component fibers comprising 5 to 95 percent by weight of a first component and 5 to 95 percent by weight of an ethylene-based polymer composition, characterized by specific properties including Comonomer Distribution Constant, vinyl unsaturation, zero shear viscosity ratio, density, melt index, and molecular weight distribution, which are used to create fabrics with improved softness and drapeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polyolefin compositions are used in producing fibers, then the fibers can be formed into fabrics using known techniques, but the resulting fabrics lack improved softness and drapeability
Solution Approach 1:
The patent employs a bi-component fiber structure where component A (polypropylene or polyethylene) and component B (ethylene-α-olefin copolymer with specific properties) are combined in a sheath/core configuration. This composite structure allows component A to provide structural integrity and component B to provide softness and drapeability, resolving the contradiction between fabric softness and processability.
Solution Approach 2:
The patent specifies precise parameter ranges for the ethylene-based polymer composition including comonomer content (5-30 wt%), comonomer distribution constant (50-400), vinyl unsaturation (<0.1 vinyls per 1000 carbon atoms), zero shear viscosity ratio (0.5-2.0), density (0.910-0.965 g/cm³), and molecular weight distribution (Mw/Mn: 1.5-3.5). These controlled parameters optimize both the softness/drapeability and processability of the resulting fabrics.
2Strength
If bi-component fibers with specific ethylene-based polymer composition are used, then improved softness and drapeability are achieved, but the fiber structure and composition become more complex
Solution Approach 1:
The bi-component fiber structure combines two distinct polymer components with specific functional roles. Component A provides structural framework while component B (with precisely controlled composition parameters) delivers softness and drapeability. This functional division allows each component to be optimized independently, managing complexity through clear role assignment.
Solution Approach 2:
The sheath/core structure creates local quality differentiation where the outer sheath (component A) provides structural integrity and the inner core (component B) provides softness and drapeability. This spatial separation of functions allows the fiber to exhibit different properties in different regions, achieving improved fabric characteristics while maintaining manageable structural complexity.
Data Source
AI summary
The instant invention provides bi-component fibers and fabrics made therefrom. The bi-component fiber according to the present invention comprises: (a) from 5 to 95 percent by weight of a first component comprising at least one or more first polymers, based on the total weight of the bi-component fiber; (b) from 5 to 95 percent by weight of a second component comprising at least an ethylene-based polymer composition, based on the total weight of the bicomponent fiber, wherein said ethylene-based polymer composition comprises; (i) less than or equal to 100 percent by weight of the units derived from ethylene; and (ii) less than 30 percent by weight of units derived from one or more α-olefin comonomers; wherein said ethylene-based polymer composition is characterized by having a Comonomer Distribution Constant in the range of from greater than from 100 to 400, a vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of the ethylene-based polymer composition; a zero shear viscosity ratio (ZSVR) in the range from 1 to less than 2; a density in the range of 0.920 to 0.970 g/cm3, a melt index (I2) in the range of from 10 to 40 g/10 minutes, a molecular weight distribution (Mw/Mn) in the range of from 1.8 to 3.0, and a molecular weight distribution (Mz/Mw) in the range of from less than 2; and wherein said bi-component fiber has a denier per filament in the range of from 0.5 to 10 g/9000 m.