Bicomponent Fiber Crimp Contraction via Polyether Blending
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Solution Overview
Problem
Existing bicomponent fibers made from poly(trimethylene terephthalate) lack substantial crimp contraction, dyeability, and softness, particularly when both components contain significant amounts of the same poly(trimethylene terephthalate) without incorporating polyether-based components.
Innovation Solution
A bicomponent fiber is developed where the first component comprises 60-100% poly(trimethylene terephthalate) and the second component includes poly(trimethylene terephthalate) blended with polyalkylene ether repeating units, such as poly(alkylene ether) glycol, to achieve improved crimp contraction and dyeability, with a weight ratio of at least 30:70 and up to 70:30, forming side-by-side or sheath-core structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bicomponent fibers are made from poly(trimethylene terephthalate) without polyether-based components, then manufacturing simplicity is maintained, but crimp contraction, dyeability, and softness are insufficient
Solution Approach 1:
The patent applies composite materials by combining poly(trimethylene terephthalate) with polyether-based components (poly(alkylene ether) glycol or polyether ester copolymer) to create a bicomponent fiber with enhanced crimp contraction, dyeability, and softness. The first component is substantially poly(trimethylene terephthalate) while the second component contains polyether elements that provide the desired performance improvements without compromising manufacturing feasibility.
2Stability of the object's composition
If both components contain substantial amounts of the same poly(trimethylene terephthalate), then material consistency is maintained, but crimp contraction and dyeability are inadequate
Solution Approach 1:
The patent applies local quality by creating distinct functional zones within the bicomponent fiber structure. The first component is substantially poly(trimethylene terephthalate) providing structural integrity, while the second component contains polyether-based materials that provide enhanced dyeability and softness. This local differentiation of material properties within the fiber structure enables both material consistency and improved performance.
3Reliability
If polyether-based components are incorporated into bicomponent fibers, then crimp contraction and dyeability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the fiber into two distinct components with different material compositions and functions. The first component is substantially poly(trimethylene terephthalate) while the second component contains polyether-based materials. This segmentation allows each component to be optimized for its specific function while maintaining a relatively simple bicomponent manufacturing process.
4Reliability
If polyether-based components are added to achieve softness and dyeability, then fiber performance is enhanced, but the number of polymer components increases
Solution Approach 1:
The patent applies multi-functionality by designing the second component to provide multiple benefits simultaneously. The polyether-based component (poly(alkylene ether) glycol or polyether ester copolymer) contributes to crimp contraction, dyeability, and softness all at once. This approach enhances fiber performance across multiple dimensions without requiring separate additions for each property, thereby limiting the increase in component complexity.
Data Source
AI summary
A bicomponent fiber wherein (a) the first component comprises from about 90 to 100 wt. % poly(trimethylene terephthalate) and (b) the second component is a polymer composition comprising (i) poly(trimethylene terephthalate) and (ii) polymer containing polyalkylene ether repeating units. Yarn, fiber, fabrics and carpets comprising the bicomponent fiber, as well as the process of making the bicomponent fiber, yarn, fabric, and carpet.