Crosslinked Bicomponent TPU Fiber Melt Spinning
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Solution Overview
Problem
Current bicomponent fibers produced by solution spinning processes often contain impurities like solvents and monomers, which affect mechanical properties and human health, and existing melt-spinning processes are limited in producing thermoplastic polyurethane fibers with high elasticity and durability for diverse knitting or woven products.
Innovation Solution
A bicomponent fiber comprising thermoplastic polyurethane components, at least one of which is cross-linked by a crosslinker, is prepared using a melt-spinning process, resulting in a fiber with superior recovery, heat-bonding behavior, dyeability, and chemical resistance, suitable for high-elasticity applications like lady underwear and pantyhose.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solution spinning process is used to produce bicomponent fibers, then fiber production is achieved, but impurities such as solvents and monomers are included in the final fibers affecting mechanical property and human health
Solution Approach 1:
The patent changes the fundamental parameter of the spinning process from solution spinning to melt spinning. This parameter change eliminates the need for solvents entirely, as the polymer is spun directly from the melt state. The process uses heat to melt the thermoplastic polyurethane components, which are then extruded through a spinneret and solidified upon cooling, producing fibers free from solvent and monomer impurities.
2Object-affected harmful factors
If melt-spinning process is used for preparing polyester and nylon fibers, then solvent-free fibers are produced, but this process is seldom used for preparing thermoplastic polyurethane fibers
Solution Approach 1:
The patent makes the melt-spinning process universally applicable to thermoplastic polyurethane by designing a bicomponent fiber system where both components are thermoplastic polyurethanes with different melting points. The process incorporates crosslinking agents that react during or after spinning to provide structural stability. This universal approach allows melt-spinning to be successfully applied to TPU, overcoming previous limitations and enabling solvent-free production of elastic fibers.
3Reliability
If bicomponent fiber with different melting point polymers is created, then heat-bonding behavior is improved, but polymer selection and process complexity increase
Solution Approach 1:
The patent applies local quality by creating a bicomponent fiber where one component (the sheath or matrix) has a lower melting point and the other component (the core or dispersed phase) has a higher melting point. The lower melting point component melts first during heat bonding to create adhesion, while the higher melting point component remains intact to maintain structural integrity. This localized differentiation of melting properties enables effective heat bonding without excessive complexity.
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
The cross-linked bicomponent fiber achieves excellent elastic extensibility and heat bonding properties, ensuring high supportability and comfort in stretchable clothing while eliminating solvent content, thus addressing the limitations of existing fibers.
Implementation Method 1
at least one of components i) and ii) is crosslinked by a crosslinker to form at least one polymer of polymer i) and polymer ii)
Implementation Method 2
A bicomponent fiber comprising thermoplastic polyurethane components, at least one of which is cross-linked by a crosslinker, is prepared using a melt-spinning process
Implementation Method 3
the bicomponent fiber... is superior in high recovery, heat-bonding behavior, dyeability and chemical-resistance
Data Source
AI summary
The present invention relates to a bicomponent fiber, comprising i) a first thermoplastic polyurethane component;and ii) a second thermoplastic polyurethane component, which may be the same as or different from component i), with at least one of components i) and ii) crosslinked by a crosslinker to form at least one polymer of polymer i) and polymer ii), of which polymer i) has a melting point of at least 10˚C higher than that of polymer ii), and the fiber size being between 8 denier and 300 denier, more preferably between 10 denier and 100 denier. The bicomponent fibers of the present invention are superior in heat-bonding behavior and recovery, and may be dyeability and chemical-resistance.