A method to make bicomponent fibers and articles comprising the same

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Solution Overview

Problem

The manufacturing of bicomponent fibers often requires specific intrinsic viscosities of polyester starting materials, which can be expensive and not readily available, leading to compromises in fiber properties or manufacturing processes to achieve desired performance characteristics.

Innovation Solution

A method involving extruding two independent melt streams, combining them in a spinneret, quenching, drawing, heat setting, and winding bicomponent fibers, where the first component has a lower moisture level than the second, allowing for control of intrinsic viscosity and optimization of fiber properties without being limited to specific polymer viscosities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If specific intrinsic viscosity polyester starting materials are used, then desired performance characteristics of bicomponent fibers are achieved, but the materials are expensive and not readily available

Engineering Contradiction:
Improveperformance characteristicsVSAvoidavailability and cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the parameter of moisture level in polyester pellets from a fixed specification to a controlled variable. By adjusting moisture content (e.g., from 0.02% to 0.5-2.0%), the intrinsic viscosity of the extruded polymer can be modified to achieve desired fiber performance characteristics using readily available, inexpensive starting materials rather than requiring expensive pre-specified viscosity materials

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent performs preliminary moisture adjustment to polyester pellets before extrusion. By controlling the moisture level of starting materials prior to the extrusion process, the intrinsic viscosity of the extruded polymer is predetermined and controlled, allowing use of common inexpensive materials while achieving specific performance characteristics

Inventive Principle:
Principle #10Preliminary action

2Ease of manufacture

If compromises are made in fiber manufacturing process or physical properties, then inexpensive and readily available materials can be used, but desired performance characteristics cannot be achieved

Engineering Contradiction:
Improvematerial cost and availabilityVSAvoidperformance characteristics
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the parameter of moisture level in polyester pellets from a fixed specification to a controlled variable. By adjusting moisture content (e.g., from 0.02% to 0.5-2.0%), the intrinsic viscosity of the extruded polymer can be modified to achieve desired fiber performance characteristics using readily available, inexpensive starting materials rather than requiring expensive pre-specified viscosity materials

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical/physical approach of selecting materials with specific intrinsic viscosities with a chemical approach of controlling moisture-induced hydrolysis during extrusion. This substitution allows inexpensive materials to be transformed into fibers with desired performance characteristics through controlled chemical modification rather than relying on expensive pre-selected materials

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method enables the use of inexpensive polymers and optimizes bulk fiber properties, allowing for increased stretch measurement values in bicomponent fibers, ranging from 10% to 85%, while maintaining control over crimp and processing characteristics.

Implementation Method 1

extruding a first and second component on a spinning machine capable of producing two or more independent melt streams

Methodology Applied
Scientific EffectExtrusion: Extrusion

Implementation Method 2

quenching in air the bicomponent fibers produced in step (b)

Methodology Applied
Scientific EffectQuenching: Cooling

Implementation Method 3

drawing and heat setting the quenched bicomponent fibers

Methodology Applied
Scientific EffectHeat setting: Heat Treatment

Data Source

PatentUS20230257909A1A method to make bicomponent fibers and articles comprising the same
Publication Date: 2023.08.17 COVATION INC

AI summary

The disclosure generally relates to bicomponent fibers, and more particularly, methods to make bicomponent fibers and articles comprising them, wherein a first extruded component has a moisture level less than a second extruded component. The bicomponent fibers may comprise polyesters and are useful in articles such as carpets and fabrics.