Modified Cross-Section Fiber Asymmetric Splitting
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Solution Overview
Problem
Existing splittable conjugate fibers require high external stress for splitting due to their circular cross-section and large bonding areas between components, limiting their splittability and resulting in nonwoven fabrics with insufficient strength.
Innovation Solution
A modified cross-section fiber configuration featuring multiple conjugate fiber structures connected by a third thermoplastic resin with a higher melting point, where the second thermoplastic resin covers the third, reducing the bonding area and facilitating easier splitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular cross-section structure with large bonding area between components is used, then the fiber structure is simple and easy to manufacture, but high external stress is required for splitting reducing splittability
Solution Approach 1:
The patent applies asymmetry by changing the fiber cross-section from a circular shape to an asymmetric shape with a concave portion. This asymmetric geometry creates a natural stress concentration point that facilitates splitting along the interface between the first and second thermoplastic resins, thereby improving splittability without requiring excessive external stress while maintaining manufacturing simplicity
Solution Approach 2:
The patent segments the fiber structure by introducing a connected body that divides the continuous bonding area into discrete connection points. This segmentation reduces the overall bonding area between components, allowing the fiber to split more easily into predetermined portions while still maintaining structural integrity where needed
2Stability of the object's composition
If a large bonding area between component A and component B is used, then the fiber structure is stable, but high external stress such as jet of high-pressure water stream is required during splitting
Solution Approach 1:
The patent applies local quality by creating regions of different bonding characteristics within the fiber structure. The connected body provides localized bonding areas with controlled adhesion strength, while other regions have reduced bonding. This allows the fiber to maintain stability in connected regions while enabling easy splitting in designated areas with lower force requirements
Solution Approach 2:
The connected body acts as an intermediary element between the first and second thermoplastic resins. It provides controlled bonding points that maintain structural stability while facilitating splitting by creating a intermediate bonding layer that can be broken with lower external stress compared to direct component bonding
3Strength
If the fiber has structure in which bonding area between component A and component B is basically large, then the fiber maintains structural integrity, but splittability is insufficient and further improvement is desired
Solution Approach 1:
The connected body segments the bonding interface into discrete connection points rather than a continuous large bonding area. This segmentation maintains structural integrity at the connection points while creating natural separation zones that improve splittability, allowing the fiber to divide into predetermined portions with controlled force
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 modified fiber design enhances splittability, allowing for the efficient production of fine conjugate fibers and resulting in nonwoven fabrics with improved strength and properties such as glossiness and moisture discharge.
Implementation Method 1
the connected body further comprises the second thermoplastic resin and has structure in which a periphery of the third thermoplastic resin is covered with the second thermoplastic resin
Implementation Method 2
the second thermoplastic resin comprised in the connected body, and the second thermoplastic resin comprised in the conjugate fiber structure are melted and united
Data Source
Figure 1(a)~1(f)
Figure 2
Figure 3
AI summary
In particular, an object is to provide a modified cross-section fiber that is split and used and thus can efficiently produce a fine conjugate fiber. The present invention relates to a modified cross-section fiber comprising: (1) a plurality of pieces of conjugate fiber structures comprising a first thermoplastic resin and a second thermoplastic resin having a lower melting or softening point than the first thermoplastic resin and (2) a connected body comprising a third thermoplastic resin having a higher melting or softening point than the second thermoplastic resin, wherein, in an arbitrary fiber cross-section, at least two pieces of the conjugated fiber structure are connected by the connected body.