Multi-Component Fiber Crimping via ICCD Polymer Composition
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Solution Overview
Problem
There is a need to enhance the curliness of polyethylene-based fibers for non-woven fabrics while maintaining efficient production processes, as existing methods do not effectively achieve the desired level of crimp or curliness.
Innovation Solution
A multi-component fiber is developed with a specific ethylene/alpha-olefin interpolymer composition in one region and a distinct polymer in another region, characterized by unique centroid arrangements and ICCD profile characteristics, which enhances curliness and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional multi-component fibers with different polyethylene based materials are used, then the fiber structure is simple and easy to manufacture, but the curliness or crimp is insufficient
Solution Approach 1:
The patent applies local quality by creating regions within the fiber that have different properties. Specifically, it uses an ethylene/alpha-olefin interpolymer composition with a specific comonomer composition distribution (ICCD) profile characterized by a low temperature peak and a high temperature peak, where the high temperature peak has a full width at half maximum of less than 6.0°C. This localized compositional variation within the fiber structure enhances curliness while maintaining manufacturability.
Solution Approach 2:
The patent employs composite materials by combining the ethylene/alpha-olefin interpolymer composition with specific ICCD characteristics with another polymer material to form a multi-component fiber. The composite structure leverages the unique crystallization behavior of the interpolymer composition to achieve enhanced curliness, resolving the contradiction between simple structure and high curliness.
2Weight of moving object
If fiber crimping is increased to reduce product weight, then the weight reduction is achieved, but the manufacturing process becomes less efficient
Solution Approach 1:
The patent applies preliminary action by incorporating the specific ethylene/alpha-olefin interpolymer composition with the defined ICCD profile directly into the fiber during the spinning process. The comonomer composition distribution is predetermined and built into the polymer structure before fiber formation, so that curliness is achieved inherently during manufacturing rather than requiring post-processing crimping steps, thus maintaining high manufacturing efficiency while reducing product weight.
Data Source
AI summary
Disclosed is a curly fiber having a fiber centroid and comprising a first region having a first centroid and a second region wherein the first region comprises an ethylene/alpha olefin interpolymer composition in an amount of at least 75 weight percent based on total weight of the first region and wherein the ethylene/alpha olefin interpolymer composition is characterized by a low temperature peak and a high temperature peak on an elution profile via improved comonomer composition distribution (ICCD) procedure, and a full width at half maximum of the high temperature peak is less than 6.0° C. and the second region is a material comprising a polymer which is different from the ethylene/alpha-olefin interpolymer of the first region and wherein the regions are arranged such that at least one of the first centroid and the second centroid is not the same as the fiber centroid.