Low-pill polyester fiber with inorganic shell
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Solution Overview
Problem
Current methods for producing low-pilling polyester fibers often compromise tensile strength or processability, and existing solutions fail to consistently maintain improved pilling behavior, especially after dyeing.
Innovation Solution
Incorporating inorganic or mineral particles during the melt spinning process of polyester fibers, which enhances pilling behavior without compromising tensile strength or processability, and these particles are integrated into the polyester matrix to prevent unforeseen events during further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the transverse strength of polyester fibers is reduced to improve pilling behavior, then pilling resistance is improved, but tensile strength is reduced too much compromising further processing
Solution Approach 1:
The invention divides the fiber structure into two distinct functional components: a core region containing the polyester polymer providing tensile strength, and a shell region containing inorganic particles providing low transverse strength. This segmentation allows each region to independently fulfill its specific function without compromising the other.
Solution Approach 2:
The invention applies different material properties to different parts of the fiber structure. The core maintains high strength polyester characteristics while the shell incorporates inorganic particles with low transverse strength. This local differentiation enables the fiber to exhibit high tensile strength overall while having reduced transverse strength at the surface level where pilling occurs.
2Ease of manufacture
If crosslinkers are used to increase melt viscosity to maintain processability with lower molecular weight, then processability is improved, but device complexity increases
Solution Approach 1:
The invention changes the fundamental parameter of fiber composition by incorporating inorganic particles into the polymer matrix during extrusion. This compositional change allows the use of lower molecular weight polymers without requiring complex crosslinking chemistry or specialized processing equipment, thereby simplifying the overall manufacturing process.
3Object-affected harmful factors
If temporary bridging compounds are added to reduce transverse strength, then pilling behavior is improved, but elongation at break becomes too high preventing processing with cotton fibers
Solution Approach 1:
The invention creates a composite fiber structure combining organic polyester polymer with inorganic particles. The inorganic particles in the shell region provide the desired low transverse strength for pilling resistance while the core polyester maintains appropriate mechanical properties including controlled elongation, enabling processing with cotton fibers and other conventional textile processes.
Data Source
AI summary
The present invention relates to polyester fibers that are modified to have low-pill characteristics by the addition of 0.5 to 10 wt% inorganic particles with a particle size in the range from 0.5 µm to 5 µm. The low-pill polyester fibers according to the invention have good properties for usage as textiles that remain intact even after high-temperature dyeing in acidic media. Textile sheet materials can be produced from the fibers according to the invention.