Fiber Bundle Spiral Crimping for Web Bulk
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Solution Overview
Problem
Current methods for spreading thermoplastic, conjugate, continuous fibers to create a uniform web with high bulk and soft touch are inefficient, costly, and complicate the manufacturing process, particularly in producing sanitary products and wiping components, as they require complex equipment and result in inconsistent fiber density and bulkiness.
Innovation Solution
A fiber bundle with specific denier, crimp, and density characteristics, where the center of gravity of conjugate components varies in the fiber cross-section, is drawn and spread to exhibit spiral crimping, resulting in a web with high bulk and excellent soft touch, achieved through controlled drawing and heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic conjugate continuous fibers are bundled in a state of high fiber density for packaging and physical distribution, then the fiber bundle is easy to handle and store, but the fibers cannot be effectively spread to obtain a uniform web with high bulk
Solution Approach 1:
The fiber bundle is preliminarily bundled in a high-density state for easy handling and storage during packaging and physical distribution. The latent crimp structure is prepared in advance within the fibers, which will be activated during the spreading step to achieve effective opening and high bulk web formation without requiring complex equipment.
Solution Approach 2:
The fiber bundle exhibits different physical states at different stages: high fiber density during packaging and physical distribution for ease of handling, then transitions to a spread state with low fiber density and high bulk during the spreading step. This parameter change is achieved through the latent crimp structure that activates under drawing tension.
2Manufacturing precision
If complex equipment and methods are used to spread fiber bundles and obtain uniform webs, then the web uniformity and bulk can be improved, but the production cost and process complexity increase significantly
Solution Approach 1:
The fiber bundle itself possesses the latent crimp structure that enables self-opening during the spreading step. The latent crimp acts as an internal mechanism that automatically opens the fibers when drawing tension is applied, eliminating the need for complex external equipment like sliding plates or sophisticated spreading mechanisms. This self-service approach achieves web uniformity and high bulk while keeping equipment simple.
Solution Approach 2:
The spreading function is extracted from complex external equipment and embedded directly into the fiber bundle structure itself through the latent crimp. Instead of using external devices to force fibers apart, the latent crimp structure inherently provides the opening mechanism, simplifying the overall system while maintaining web quality.
3Strength
If the fiber bundle is spread to obtain high bulk web, then the web softness and absorbency are improved, but the production time and process complexity increase
Solution Approach 1:
The latent crimp structure is prepared in advance during fiber manufacturing, so that during the spreading step, the fibers can quickly open and form a high bulk web without requiring extended processing time. The preliminary preparation of the crimp structure enables rapid expansion when drawing tension is applied.
Solution Approach 2:
The fiber bundle rapidly transitions from a compact high-density state to an expanded low-density high-bulk state during the spreading step. This parameter change occurs quickly under drawing tension, achieving web softness and bulk without significant production time loss.
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 method allows for efficient production of a web with uniform high bulk and soft touch, suitable for absorbent products, wiping members, and filters, by effectively opening the fiber bundle and maintaining fiber strength, while reducing production costs and complexity.
Implementation Method 1
the thermoplastic, conjugate, continuous fibers that make up the fiber bundle are bundled in a state of high fiber density in packaging, physical distribution, and pull-up steps, but then exhibit spiral crimping when the fiber bundle is drawn in an spreading step
Implementation Method 2
a method for manufacturing a web, in which this fiber bundle is used... comprising a step of drawing and spreading the fiber bundle
Data Source
AI summary
There is provided a fiber bundle that strikes an excellent balance between the properties and performance of the resulting web and the finished products obtained from this web, and cost, ease of work, and productivity. There is also provided a method for manufacturing a web using this fiber bundle. There is also provided a web that is uniform and has excellent soft touch and bulkiness. This is achieved by a fiber bundle with a total denier of 10,000 to 500,000 dtex, obtained by bundling thermoplastic, conjugate, continuous fibers that have a single filament denier of 0.5 to 100 dtex/f and in which the center of gravity of conjugate components varies among the conjugate components in a fiber cross section, wherein the thermoplastic, conjugate, continuous fibers that make up the fiber bundle have a spontaneous crimp of 8 to 30 crimps per 2.54 cm, the fiber bundle density as defined by D1/(W1×L1) (where D1 is the total denier, W1 is the fiber bundle width, and L1 is the fiber bundle thickness) is 100 to 2000 dtex/mm2, and the density ratio by spreading (the web density/fiber bundle density after spreading by drawing to a ratio of 1.6 in a pinch roller spreading machine at a rate of 25 m/min and a fiber bundle temperature of 25° C.) is 0.10 or less.