Hot-melt Adhesive Polyester Conjugate Fiber Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing ultrafine fibers, particularly those combining polyester and olefin polymers, face challenges in achieving stable flow-drawing processes, high productivity, and uniform fiber properties due to issues like fiber breakage, unevenness, and low productivity.
Innovation Solution
Conjugating an olefin polymer with a polyester-based polymer to create a hot-melt adhesive conjugate fiber, which stabilizes the flow-drawing process, allowing for the production of heat-shrinkable and ultrafine fibers with high productivity and runnability by controlling the birefringence and orientation of the polymer components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drawing is performed at high magnification to produce ultrafine fibers, then fiber fineness is improved, but fiber breakage increases and productivity decreases
Solution Approach 1:
The patent applies parameter changes by performing drawing treatment at elevated temperatures (above the glass transition temperature of the polyester component) to modify the viscoelastic properties of the polymer. This enables the fiber to be drawn at higher magnifications without excessive breakage, as the thermal energy allows the polymer chains to deform more readily while maintaining structural integrity. The temperature parameter is critical to achieving both high fineness and acceptable productivity.
2Manufacturing precision
If drawing temperature is increased to enable high magnification drawing, then fiber fineness is improved, but fiber structure development is restricted and process stability deteriorates
Solution Approach 1:
The patent employs composite materials by combining polyester (providing structural stability and heat resistance) with olefin polymer (providing flowability and drawing capability). This composite structure allows the fiber to withstand the drawing process at high temperatures and magnifications while maintaining process stability. The polyester component prevents excessive softening and structural collapse, while the olefin component facilitates the flow-drawing mechanism.
3Reliability
If olefin polymer is used alone for fiber production, then chemical resistance and safety are improved, but drawing capability and fiber structure development are limited
Solution Approach 1:
The patent uses composite materials to overcome the limitations of olefin polymer alone. By combining olefin (providing chemical resistance and safety) with polyester (providing drawing capability and structural development), the resulting conjugate fiber achieves both chemical resistance and excellent drawing performance. The polyester component enables the fiber to be drawn at high magnifications while maintaining the chemical resistance properties of the olefin.
4Speed
If infrared irradiation is used for rapid heating to achieve flow-drawing state, then drawing speed is improved, but heating area is restricted and productivity decreases
Solution Approach 1:
The patent replaces the mechanical/physical infrared irradiation heating method with a thermal field heating approach using heated rollers or zones. This substitution allows for more uniform and scalable heating across the entire fiber bundle, enabling simultaneous processing of multiple fiber lines. The thermal field method eliminates the restricted heating area problem of infrared beams while maintaining rapid heating capability to achieve the flow-drawing state.
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 solution enables the production of ultrafine hot-melt adhesive conjugate fibers with enhanced strength, thermal stability, and high productivity, suitable for applications in hygiene products and industrial materials, by achieving stable flow-drawing and high drawing magnification.
Implementation Method 1
the undrawn yarn comprising the olefin material has been crystallized, or tends to crystallize during the drawing process
Implementation Method 2
creating a flow-drawing state by performing a first stage drawing treatment at a high temperature and forming fine fibers while restricting fiber structure development
Implementation Method 3
a conjugate fiber having both the proper amount of heat shrinkage and hot-melt adhesive properties
Implementation Method 4
a conjugate fiber comprising a polyester polymer and an olefin polymer... hot-melt adhesive conjugate fiber
Data Source
AI summary
To obtain an ultrafine heat-shrinkable conjugate fiber at high productivity, in which a flow-drawing state of a polyester undrawn yarn is realized easily and stably. By drawing undrawn yarn comprising a conjugated polyester polymer and olefin polymer, a flow-drawing process can be easily and stably realized using conventional production facilities; and the heat-shrinkable fiber, a drawn intermediate, and an ultrafine hot-melt adhesive conjugate fiber produced by redrawing the drawn intermediate of the present invention can be obtained with high productivity and excellent runnability. More specifically, the ultrafine hot-melt adhesive conjugate fiber obtained by redrawing can be drawn at a heretofore unseen high drawing magnification, and the fiber structure of the olefin polymer constituting part of the conjugate fiber is markedly developed. The heat-shrinkable fiber and ultrafine hot-melt adhesive conjugate fiber thus obtained can be suitably used in hygiene products and industrial materials by utilizing these features.