Polyester Binder Fiber Composite for High-Strength Nonwovens
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Solution Overview
Problem
Conventional polyester binder fibers for papermaking face challenges with fiber breakage and reduced water dispersibility due to low tenacity, and existing technologies do not effectively utilize polyester fibers with high adhesiveness for producing strong fiber structures.
Innovation Solution
A polyester binder fiber is developed by blending polyester with a polymer having a specific repeating unit, such as polymethyl methacrylate, to achieve high adhesiveness and small fineness, allowing for the production of strong fiber structures with improved spinnability and tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the single fiber fineness of polyester binder fiber is reduced to less than 1.0 dtex to improve adhesiveness, then adhesiveness is improved, but fiber breakage increases due to small tenacity of monofilament
Solution Approach 1:
The patent creates a composite binder fiber by blending polyester with a small amount of polymer (0.1-5% by weight), such as polymethyl methacrylate or poly-4-methyl-pentene-1. This composite structure allows the fiber to maintain fine fineness (<1.0 dtex) for high adhesiveness while the blended polymer reinforces the fiber to prevent breakage due to the small tenacity of monofilament fibers.
2Strength
If undrawn polyester fiber with small fineness is produced to achieve high adhesiveness, then adhesiveness improves, but water dispersibility deteriorates
Solution Approach 1:
The patent employs composite materials by blending polyester with specific polymers in controlled proportions. This composite structure enables the production of undrawn fibers with fineness below 1.0 dtex that maintain both high adhesiveness and improved water dispersibility, resolving the contradiction between these two properties.
Solution Approach 2:
The patent changes the chemical composition parameters by introducing blended polymers at specific concentrations (0.1-5% by weight). This parameter modification allows the fiber to achieve desirable fineness and adhesiveness while maintaining water dispersibility through the specific chemical properties of the blended polymer.
3Strength
If polyester fiber with high adhesiveness is used to produce strong fiber structures, then fiber structure strength improves, but basis weight must be maintained which increases cost
Solution Approach 1:
The patent uses composite binder fibers with blended polymers to achieve high adhesiveness and fiber structure strength. This allows reduction in basis weight while maintaining required strength levels, as the composite structure provides superior bonding efficiency per unit weight compared to conventional binder fibers.
Data Source
AI summary
To provide a polyester binder fiber with improved adhesiveness and a fiber structure containing the polyester binder. (1) A polyester binder fiber includes a polyester and a polymer having a repeating unit represented by the following formula (1) in a proportion of 0.1 to 5.0 mass% based on the mass of the polyester, and the polyester binder fiber has a crystallization temperature measured by differential calorimetry in a range of 100 to 250°C; (2) a fiber structure includes the polyester binder fibers, and polyester subject fibers without a crystallization temperature, the polyester subject fibers being bonded via the polyester binder fiber. In the forumla R1 and R2 are substituents each comprising arbitrary atoms chosen from C, H, N, O, S, P, and a halogen atom, the sum of the molecular weights of R1 and R2 is 40 or more, and n is a positive integer.