Eccentric Core-Sheath Conjugate Fiber Compression Resistance
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Solution Overview
Problem
Existing thermal bonding conjugate fibers fail to provide adequate compression resistance and retain bulkiness under heavy loads, as they often rely on materials like thermoplastic elastomers that are not suitable for direct skin contact or have limited compatibility for maintaining fiber cross-section configurations.
Innovation Solution
A thermal bonding conjugate fiber with an eccentric core-sheath structure, where a polyester resin forms the core and a polyolefin resin with a lower melting point forms the sheath, exhibiting a thermal shrinkage ratio of at least 20% after heat treatment, and is blended with other fibers to create a nonwoven fabric with improved compression resistance and bulkiness retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic elastomer is used to improve recovery from compression, then elasticity is improved, but the fiber becomes sticky and unsuitable for direct skin contact
Solution Approach 1:
The fiber is divided into two distinct components: a polyester resin core that provides structural integrity and elasticity, and a polyolefin resin sheath that prevents stickiness and enables thermal bonding. This segmentation allows each component to fulfill its specific function without the drawbacks of using thermoplastic elastomer alone.
Solution Approach 2:
The invention uses a composite structure combining polyester resin and polyolefin resin in a core-sheath configuration. The polyester core provides the desired elastic recovery, while the polyolefin sheath prevents stickiness and enables thermal bonding processing, creating a material that overcomes the limitations of single-material approaches.
2Strength
If side-by-side configuration is used to improve recovery from compression, then elasticity is improved, but the combinations of resins with good compatibility are limited
Solution Approach 1:
The fiber structure is segmented into core and sheath components with distinct functions. The polyester core can be combined with various polyolefin sheaths (polyethylene, polypropylene, etc.), providing versatile resin combinations while maintaining good compatibility through the core-sheath architecture that minimizes direct interaction between incompatible polymers.
3Volume of stationary object
If conventional thermal bonding fibers are used, then bulkiness is obtained, but compression resistance and bulkiness retention under heavy load are insufficient
Solution Approach 1:
The invention changes the key parameter of thermal shrinkage ratio to at least 20% through specific fiber construction and heat treatment conditions. This parameter change enables the fiber to undergo significant contraction during thermal bonding, creating a tightly bonded nonwoven fabric structure that maintains bulkiness while providing excellent compression resistance and bulkiness retention under load.
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 nonwoven fabric maintains bulkiness under light loads and reduces the rate of bulkiness decrease under heavy loads, achieving excellent compression resistance while also incorporating inorganic fine particles for enhanced softness and performance.
Implementation Method 1
a second component comprising a polyolefin resin having a melting point at least 15° C. lower than a melting point of the polyester resin constitutes a sheath
Implementation Method 2
a shrinkage ratio after a heat treatment of 120° C. is at least 20%
Data Source
AI summary
This invention provides a thermal bonding conjugate fiber having excellent compression resistance and nonwoven fabric using the same. Particularly, the nonwoven fabric retains bulkiness obtained under a light load even under a heavy load and reduces a decrease in bulkiness from under a light load to under a heavy load. The thermal bonding conjugate fiber has an eccentric core-sheath structure in which a first component including a polyester resin constitutes a core and a second component including a polyolefin resin having a melting point at least 15° C. lower than that of the polyester resin constitutes a sheath, and a shrinkage ratio of the conjugate fiber after a heat treatment of 120° C. is at least 20%. The nonwoven fabric is obtained by blending the thermal bonding conjugate fiber at a blend ratio of 10 to 60 wt % with one or more types of different thermal bonding fibers.