Eccentric Core-Sheath Composite Fiber for Stretchable Textiles
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Solution Overview
Problem
Existing fibers fail to provide a balance of stretchability, wear resistance, and appearance quality, often resulting in crinkles, streaks, and uneven dyeing due to interfacial separation and stiffness, particularly in fabrics made from composite fibers with latent crimpiness.
Innovation Solution
An eccentric core-sheath composite fiber with a cross-sectional configuration where one polymer is entirely covered by another, differing in melt viscosity, and a mixed-filament yarn with dispersed single filaments of varying cross-sectional configurations to achieve a three-dimensional spiral structure and improved dispersion for enhanced stretchability and natural appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If composite fibers with latent crimpiness are used to provide stretchability, then fabric stretchability is improved, but interfacial separation occurs causing whitening and fluffing that decrease appearance quality
Solution Approach 1:
The patent applies nested doll by placing one polymer ingredient entirely within another polymer ingredient to form a core-sheath composite fiber structure. The inner polymer (ingredient A) is completely enclosed by the outer polymer (ingredient B), creating a nested configuration that prevents interfacial separation while maintaining the shrinkage difference needed for latent crimpiness and fabric stretchability.
Solution Approach 2:
The patent applies asymmetry by creating an eccentric core-sheath structure where the inner polymer is positioned off-center within the outer polymer. This asymmetric arrangement produces uneven shrinkage during heat treatment, generating the latent crimpiness and spiral structure necessary for fabric stretchability, while the complete enclosure prevents interfacial separation and maintains appearance quality.
2Illumination intensity
If fibers are made with enhanced fineness to improve smooth feeling and softness, then aesthetic properties are improved, but fabric tightness and stiffness increase giving a tight sense of wear
Solution Approach 1:
The patent applies parameter changes by controlling the fineness of the composite fiber within a specific range (1.5-3.0 dtex) and adjusting the shrinkage difference between the two polymer ingredients. This optimized parameter combination maintains smooth feeling and aesthetic properties while preventing excessive fabric tightness and stiffness, thereby improving comfort of wear.
3Adaptability or versatility
If polyurethane-based fibers are incorporated to impart stretchability, then fabric stretchability is improved, but the fabric becomes stiff and difficult to dye
Solution Approach 1:
The patent applies homogeneity by using two polyester-based polymer ingredients that are chemically similar and compatible. Both ingredients can be dyed with the same polyester dyes, ensuring uniform dyeing throughout the composite fiber without the complexity associated with multi-component systems. The chemical homogeneity eliminates dyeing difficulties while maintaining stretchability through physical structure rather than chemical composition.
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 solution provides fabrics with sufficient stretchability, wear resistance, and a smooth, even appearance free from crinkles and streaks, while maintaining the comfort and natural graininess of the yarn, with improved dyeing uniformity and processability.
Implementation Method 1
a first ingredient (A) and a second ingredient (B) differing in shrinkage, in which the ingredient (A) having the higher shrinkage is positioned in an eccentric manner in the cross-section of the composite fiber
Implementation Method 2
The structure expands and contracts like a spring, and stretchability can hence be imparted to the fabric
Data Source
AI summary
A fiber material combines both stretchability and wear resistance, has a uniform and bump- and streak-free outer appearance, and has a smooth, delicate texture. The eccentric core-sheath composite fiber is characterized in that in the cross-section of a composite fiber composed of two different polymers, an A-component is completely covered by a B-component, a ratio S/D, or the minimum thickness S of the thickness of the B-component covering the A-component to a fiber diameter D, is 0.01 to 0.1, and a perimeter of a portion of fiber, where the thickness is 1.05 times or less the minimum thickness S, is at least one third of the perimeter of the fiber overall.