Splittable Conjugate Fiber Cross-Section Design for Thermal Bonding
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Solution Overview
Problem
Splittable conjugate fibers comprising polyester and polyolefin face challenges with low thermal bond strength and poor spinnability due to compatibility issues, leading to debonding under physical impact and poor nonwoven fabric texture.
Innovation Solution
A splittable conjugate fiber design with polyester segments extending from the center to the outer edge, where at least one segment is exposed and one is unexposed, enhancing thermal bondability and splittability, and an aggregate of these fibers in specific proportions to improve fibrous form texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a splittable conjugate fiber comprises polyester and polyolefin components, then splittability is improved, but thermal bondability to polyolefin-based binder fiber deteriorates due to low compatibility between polyester and polyolefin
Solution Approach 1:
The fiber cross-section is designed with non-uniform polyester segment distribution, where some polyester segments extend to the outer edge (exposed) and others do not (unexposed). This local variation in composition creates different functional zones: exposed polyester segments provide splittability while unexposed segments maintain thermal bondability through polyolefin contact with binder fibers.
Solution Approach 2:
The conjugate fiber combines polyester and polyolefin materials in a specific spatial arrangement within the same fiber structure. This composite structure allows the fiber to simultaneously exhibit properties of both materials: polyester provides strength and splittability, while polyolefin provides thermal bondability compatible with polyolefin binder fibers.
2Ease of operation
If polyester segments are exposed at the outer edge of the fiber, then splittability is improved, but thermal bondability deteriorates due to reduced polyolefin contact with binder fiber
Solution Approach 1:
The fiber cross-section is designed with non-uniform polyester segment distribution, where some polyester segments extend to the outer edge (exposed) and others do not (unexposed). This local variation in composition creates different functional zones: exposed polyester segments provide splittability while unexposed segments maintain thermal bondability through polyolefin contact with binder fibers.
3Productivity
If a loose aggregate of splittable conjugate fibers is subjected to physical impact for splitting, then microfibers are obtained, but fibers are shunted around the point of impact causing holes or poor texture
Solution Approach 1:
The fiber cross-section incorporates a hollow structure with curved surfaces rather than sharp edges. This curved geometry distributes the impact force more evenly across the fiber structure during splitting, preventing localized stress concentration that would cause fiber shunting and hole formation, while still enabling effective splitting into microfibers.
Solution Approach 2:
The conjugate fiber combines polyester and polyolefin materials in a specific spatial arrangement within the same fiber structure. This composite structure provides both the structural integrity needed to resist excessive deformation during impact and the controlled splitting capability to produce uniform microfibers with good texture.
4Ease of operation
If polyester and polyolefin are used in conjugate fiber, then splittability is achieved, but spinnability deteriorates due to poor compatibility and difficulty in stabilizing fibrous state
Solution Approach 1:
The fiber is designed with specific parameter controls including the hollow ratio (5-40%) and the W/L ratio (0.25-2.5), where W is the average length of the outer arc and L is the average length from the hollow to the outer edge of individual segments. These parameter optimizations stabilize the fibrous state during spinning while maintaining splittability, resolving the compatibility issue between polyester and polyolefin.
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 achieves high thermal bondability and splittability, resulting in a fibrous form with improved denseness and texture, effectively addressing the limitations of existing fibers.
Implementation Method 1
The splittable conjugate fiber obtained is split into many fibers by applying a physical stress thereto or utilizing, e.g., a difference in contraction with a chemical between the resins
Implementation Method 2
the splittable conjugate fiber comprising the polyester and the polyolefin is excellent in thermal bondability to a polyolefin-based binder fiber
Data Source
Figure 1~2
AI summary
A splittable conjugate fiber comprising a polyester segment and a polyolefin segment, wherein the splittable conjugate fiber comprises two or more parts of the polyester segment extending from a center of the fiber toward an outer edge of the fiber in a cross-sectional configuration perpendicular to its longitudinal direction, in which at least one of the two or more parts of the polyester segment extending from the center of the fiber toward the outer edge of the fiber is exposed at the outer edge of the fiber and at least one of the two or more parts of the polyester segment extending from the center of the fiber toward the outer edge of the fiber is unexposed at the outer edge of the fiber.