Multilobal Fiber Fibrillation for Microdenier Fabric Strength
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Solution Overview
Problem
Current methods for manufacturing microdenier fibers face limitations in spinning and fiber shape flexibility due to the need for dissimilar polymers with specific properties, leading to defects and restricted polymer choices, and existing processes are not environmentally friendly or economically viable.
Innovation Solution
The development of multicomponent, multilobal fibers with a contiguous core fiber component enwrapped by a multilobal sheath fiber component, allowing for fibrillation into microdenier fibers, which can form high-strength and durable fabrics through hydroentangling, and enabling a range of fiber cross-sections and polymer combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dissimilar polymers are used to ensure fiber splitting, then fiber separability is improved, but manufacturing defects increase due to property mismatches
Solution Approach 1:
The patent applies local quality by creating a core-sheath structure where the sheath component has different properties than the core, specifically making the sheath tip regions dissimilar to promote splitting while keeping the core properties consistent for manufacturing stability. This localized differentiation allows separability without compromising overall fiber integrity during processing.
2Ease of manufacture
If segmented pie configuration is used to facilitate splitting, then fiber separability is improved, but fiber shape flexibility is reduced
Solution Approach 1:
The patent uses segmentation by dividing the sheath component into multiple lobes (trilobal, quadrilobal, etc.) that can be split into discrete segments. This segmentation enables the fiber to separate into multiple microdenier fibers while allowing flexibility in the number and arrangement of lobes, thus providing shape flexibility that the conventional segmented pie configuration lacks.
Solution Approach 2:
The patent introduces asymmetry by using multilobal cross-sections (triangular, quadrangular, or other polygonal shapes) instead of the symmetric segmented pie configuration. This asymmetric multilobal structure provides both separability and shape flexibility, allowing the fiber to be split into various configurations depending on the lobe arrangement.
3Productivity
If conventional spinning processes are used, then production efficiency is improved, but environmental impact increases
Solution Approach 1:
The patent replaces conventional mechanical spinning processes with a hydroentangling process that uses high-pressure water jets to entangle and split the fibers. This substitution eliminates or reduces the need for harsh chemicals and high-temperature processing, thereby maintaining production efficiency while reducing environmental impact.
Solution Approach 2:
The patent employs hydraulics by using high-pressure water jets in the hydroentangling process to achieve fiber separation and fabric formation. This hydraulic approach replaces conventional thermal and chemical methods, providing an environmentally friendly alternative that maintains high productivity through efficient water-based processing.
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
This approach enables the production of microdenier fibers with enhanced strength and durability, flexibility in fiber shapes, and environmentally sound processing, overcoming the limitations of previous technologies by using incompatible polymers and allowing for a variety of polymer combinations, while reducing environmental impact.
Implementation Method 1
fibrillating the multicomponent, multilobal fiber to expose the core fiber component and split the fiber into multiple microdenier fibers
Data Source
AI summary
A fabric including microdenier fibers is provided, the microdenier fibers prepared by fibrillating a multicomponent, multilobal fiber including a contiguous core fiber component enwrapped by a multilobal sheath fiber component such that the sheath fiber component forms the entire outer surface of the multicomponent fiber, wherein the core fiber component and the multilobal sheath fiber component are sized such that the multicomponent, multilobal fiber can be fibrillated to expose the core fiber component and split the fiber into multiple microdenier fibers.