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Bi-continuous, Self-bulking Fibers Disclosure Number: IPCOM000126190D
Publication Date: 2005-Jul-06
Document File: 1 page(s) / 31K

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Bi-continuous, self balking fibers result from melt spinning joined melt streams, one of which comprises syndiotactic polystyrene and the other of which comprises a melt spinnable polymer other than syndiotactic polystyrene (e.g. nylon -6.6). A yarn formed from the fiber self-balks (curls) upon stretching at room temperature.

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Bi-continuous, Self-bulking Fibers

Form bi-continuous fibers by bringing two polymer melt streams, one of which comprises syndiotactic polystyrene and the other of which comprises a melt-spinnable polymer other than syndiotactic polystyrene, into contact with one another in a die configuration that forms a monofilament fiber.  Each polymer melt stream forms a portion of the monofilament fiber, the size of the portion depending upon quantity and melt flow rates of the respective polymer melt streams. 

Any of a variety of fiber shapes and polymer dispositions may be formed including a core-shell, circular shape where one polymer melt stream forms the core and the other forms the shell, a trilobal shape where one polymer melt stream forms at least one of the lobes and the other polymer melt stream forms the balance of the shape, and a circular or cylindrical shape in which the two polymer melt streams combine in a side-by-side disposition. 

Within the resulting fibers, solidified polymer melt streams resist separation by at least one of chemical means such as compatibilization, at least at the interface, and mechanical means such as interlocking. 

Self-bulking results from application of a drawing force on a fiber that contains at least two polymeric materials that differ in one or more of shrinkage and elongation, often at different temperatures.  Spinnable polymers such as nylons tend to be high shrinkage, high elongation, and lower temperature (melt temperature and/or glass transition temperature) materials whereas syndiotactic polystyrene is, compared to such spinnable polymers, a low shrinkage, low elongation, higher temperature material.  Because syndiotactic polystyrene does not elongate as much as the other melt-spinnable polymers, co-continuous fibers that include syndiotactic polystyrene tend to be inherently self-bulking.

Form an asymmetric side-by-side trilo...