BICOMPONENT FIBERS

Updated: April, 2004 - Raghae!dra R" #egde, At$l %ahi&a, M" '" (a)ath
*Praee! ($)ar +a!gala , Ra)aiah (-tra.
/" INTRO%UCTION
Bicomponent fibers can be defined as "extruding two polymers from the same spinneret
with both polymers contained within the same filament. A close relative is "co-spun
fiber", which is a group of filaments of different polymers, but a single component per
filament, spun from the same spinneret. The term "conugate fibers" is often used,
particularly in Asia, as synonymous with bicomponent fibers !"#.
2" BAC('ROUN%
$upont introduced the first commercial bicomponent application in the mid "%&'s. This
was a side-by-side hosiery yarn called "cantrese" and was made from two nylon
polymers, which, on retraction, formed a highly coiled elastic fiber. (n the "%)'s, various
bicomponent fibers began to be made in Asia, notably in *apan. +ery complex and
expensive spin pac,s apparently were used in the manufacturing process. These
techni-ues were found to be technically unsatisfactory and excessively expensive. .ater
in "%/%, a novel approach was developed using thin flat plates with holes and grooves to
route the polymers. This process was very flexible and -uite price effective !"#.
0" PRO%UCERS
0orldwide, *apan and 1orea led in bicomponent output with a total of 2'' million
pounds annually. The production of the 3.4. is currently around &' million pounds with
5oechst 6elanese holding the lead. 7ther 3.4. players in the Bicomponent sector include
8oss manufacturing, (nternational 9olymers (nc. and 8iber +isions. The present
production of bicomponent fibers worldwide is only a fraction of the 2: million metric
tons of manmade fiber mar,et, but the producers are confident of significant growth in
the next "' years or so !2#.
4" PO12MERS
The polymers given below can be used as either of the components in the cross sections
!;#.
9<T =polyester> 9<? polyester
?ylon &,& 96T polyester
9olypropylene 9BT polyester
?ylon & co-polyamides
9olylactic acid polystyrene
Acetal polyurethane
4oluble co polyester 5$9<, ..$9<
:. 9@7$36T(7? A?$ 6.A44(8(6AT(7?
The main obective of producing Bicomponent fibers is to exploit capabilities not existing
in either polymer alone. By this techni-ue, it is possible to produce fibers of any cross
sectional shape or geometry that can be imagined. Bicomponent fibers are commonly
classified by their fiber cross-section structures as side-by-side, sheath-core, islands-in-
the-sea and citrus fibers or segmented-pie cross-section types.
3"/ Side-4&-Side *S5S.
These fibers contain two components lying side-by-side =8ig.".>. Aenerally, these fibers
consist of two components divided along the length into two or more distinct regions.
(n most cases, the components must show very good adhesion to each otherB otherwise,
the process will result in obtaining of two fibers of different compositions. The way to
connect the two components mechanically is described in patent literature !C# and is
shown in 8ig.". =h> And =i>. Aenerally, there are several approaches for producing side-
by-side bicomponent fibersD
Two components, either in the form of solution or melt, are fed directly to the spinneret
orifices or are combined into bicomponent fibers near the orifices.
Two components are first formed into multi-layered structure and slowly fed =without
turbulence> in the orifices. The orifices are positioned so that they intersect the interfaces
of various layers of the polymer.
Two components are also formed into layered structure but the orifices do not follow
exactly the interfaces, which leads to production of fibers of a wide range of
compositions, varying from "''E of one component to "''E of the other through all
intermediate possibilities. Two polymer components are slit-extruded into a layered film,
which is then cut into stripes, drawn, cut into staple and fibrillated by a carding machine
and then crimped by heat relaxation !:#.
3"/"/ USE OF SI%E-B2-SI%E BICOMPONENT FIBERS
4ide-by-side fibers are generally used as self-crimping fibers. There are several systems
used to obtain a self-crimping fiber. 7ne of them is based on different shrin,age
characteristics of each component. All commercially available fibers are of this type.
There have been attempts to produce self-crimping fibers based on different electrometric
properties of the componentsB however, this type of self-crimping fiber is not
commercially used. 4ome types of side-by-side fibers crimp spontaneously as the
drawing tension is removed and others have "latent "crimp, appearing when certain
ambient conditions are obtained. 4ome literature mentions, "reversible "and "non-
reversible" crimp, when reversible crimp can be eliminated as the fiber is immersed in
water and reappears when the fiber is dried. This phenomenon is based on swelling
characteristics of the components. 4everal factors are crucial to the fiber curvature
developmentD The difference in the shrin,age between the components, the difference
between modulus of the components, the overall cross-sectional fiber shape and
individual cross-sectional shapes of each component, and the thic,ness of the fiber.
$ifferent melting points on the sides of the fiber are ta,en advantage of when fibers are
used as bonding fibers in thermally bonded non-woven webs. The example of such
bonding fibers is <A F <4 of 6hisso, *apan, with polyethylene as the low melting
component =Tm G ""'
o
6>, along with polypropylene !:#. 4ide-by-side fibers have also
been reported to be a base fiber for producing so called "splittable " fibers, which split in
a certain processing stage, yielding fine filaments of a sharp-edged cross section. 7ne of
the components could be removed by dissolving !&# or the fiber could split by ust
heating and the fiber would split by a flexion action !)#.
3"2 S#EAT#-CORE *S5C. FIBERS
4heath-core Bicomponent fibers are those fibers where one of the components =core> is
fully surrounded by the second component =sheath> =8ig.2>. Adhesion is not always
essential for fiber integrity. This structure is employed when it is desirable for the surface
to have the property of one of the polymers such as luster, dyeability or stability, while
the core may contribute to strength, reduced cost and the li,e. A highly contoured
interface between sheath and core can lead to mechanical interloc,ing that may be
desirable in the absence of good adhesion.
3"2"/"S#EAT#-CORE FIBER PRO%UCTION
The most common way of production of sheath-core fibers is a techni-ue where two
polymer li-uids are separately led to a position very close to the spinneret orifices and
then extruded in sheath-core form. (n the case of concentric fibers, the orifice supplying
the "core" polymer is in the center of the spinning orifice outlet and flow conditions of
core polymer fluid are strictly controlled to maintain the concentricity of both
components when spinning. <ccentric fiber production is based on several approachesD
eccentric positioning of the inner polymer channel and controlling of the supply rates of
the two component polymers !/#B introducing a varying element near the supply of the
sheath component melt !%#B introducing a stream of single component merging with
concentric sheath-core component ust before emerging from the orificeB and deformation
of spun concentric fiber by passing it over a hot edge !"'#. 7ther, rather different
techni-ues to produce sheath-core fibers are coating of spun fiber by passing through
another polymer solution !""# and spinning of copolymer into a coagulation bath
containing a-ueous latex of another polymer !"2#. Hodifications in spinneret orifices
enable one to obtain different shapes of core orIand sheath within a fiber cross-section.
There is considerable emphasis on surface tensions, viscosities and flow rates of
component melts during spinning of these fibers.
3"2"2 USE OF S#EAT#-CORE BICOMPONENT FIBERS
Besides the sheath-core bicomponent fiber used as a crimping fiber, these fibers are
widely used as bonding fibers in ?onwoven industry. The sheath of the fiber is of a lower
melting point than the core and so in an elevated temperature, the sheath melts, creating
bonding pints with adacent fibers - either bicomponent or monocomponent. The first
commercial application of sheath-core binding fiber =(.6.(. 5eterofil, !";#> has been in
carpets and upholstery fabrics. The newest trend in bicomponent fiber production is to
focus on tailoring a fiber according to the customerJs needs. A considerable emphasis was
put on the processing optimiKation =depending strictly on machinery used> and on the
desired loo, of the final product. (t appears that concentricityIeccentricity of the core
plays an important role. (f the product strength is the maor concern, concentric
bicomponent fibers are usedB if bul,iness is re-uired at the expense of strength, the
eccentric type of the fiber is used !"C#. 7ther uses of sheath-core fibers derive from
characteristics of the sheath helping to improve the overall fiber properties. A sheath-core
fiber has been reported !":# whose sheath is made of a polymer having high absorptive
power for water, thereby having obvious advantages for use in clothing. 7ther sheath-
core fibers showed better dyeability !"&#, soil resistance !")#, heat-insulating properties
!"/#, adhesion !"%# etc. 9roduction of ceramic sheath-core bicomponent fibers is another
application utiliKing the difference of sheath and core !2'#. The fiber precursors are first
spun in a sheath-core arrangement and then cured by oxidation, 3+ and electron beam,
heating or by chemical means. These fibers are used as a composite reinforcement.
3"0 MATRI6-FIBRI1 BICOMPONENT FIBERS
These are also called islands-in-the-sea fibers. Technically these are complicated
structures to ma,e and use. (n cross section, they are areas of one polymer in a matrix of
a second polymer. These types of bicomponent structure facilitate the generation of micro
denier fibers. The LislandsJ are usually a melt spinnable polymer such as nylon, polyester
or polypropylene. 9olystyrene water-soluble polyesters and plasticiKed or saponified
polyvinyl alcohol can form the sea or matrix. The finer deniers that can be obtained are
normally below '." denier !2"#.
3"0"/ PRO%UCTION OF MATRI6-FIBRI1 BICOMPONENT FIBERS
Basically, these fibers are spun from the mixture of two polymers in the re-uired
proportionB where one polymer is suspended in droplet form in the second melt. An
important feature in production of matrix-fibril fibers is the necessity for artificial cooling
of the fiber immediately below the spinneret orifices. $ifferent spinnability of the two
components would almost disable the spinnability of the mixture, except for low
concentration mixtures =less than 2'E>.
3"0"2 USE OF MATRI6-FIBRI1 BICOMPONENT FIBERS
A matrix-fibril fiber called "4ource" is produced by Allied 6hemicals .td. !22#. The fiber
is based on 9<T fibrils embedded in a matrix of ?ylon &. The presence of 9<T fibrils is
supposed to increase the modulus of the fiber, to reduce moisture regain, to reduce the
dyeability, improve the texturing ability and give the fiber a uni-ue lustrous appearance.
The fine fibers produced by this method are used in synthetic leather, specialty wipes,
ultra-high filtration media, artificial arteries and many other specialiKed applications.
3"4 SE'MENTE% PIE STRUCTURE
This structure as shown in 8ig-C is commonly referred to as "segmented pie structure" or
"citrus," Alternate pie or wedges are made of nylon and polyester. The fiber contains
around "& segments. The fibers are made in to web, carded, and fiber web is passed
through high-pressure et of air or water as to split the fibers. This splitting and
entanglement ma,es the resultant fabric more strong.
FI'" 4: SE'MENTE% PIE STRUCTURE
4ometimes it is difficult to split individual fibers, and in that case the hollow wedge
structure is used as shown in 8ig-: and 8ig &.
8ig. :D 5ollow 9ie 0edge 4tructure 8ig. &D 6onugate 4tructure

4ometimes, it becomes very difficult to card this fiber because of its different modulus
properties. (n order to overcome this problem their structure is a ltered as in 8ig-) and
8ig-/ !2;#.
8ig-) 4egmented 6ross structure 8ig-/ Tipped Trilobal 4tructure
7"0 PO12MER B1EN%S
9olyblends, of polymer alloys, are defined as homogenous or heterogeneous mixtures of
structurally different homopolymers or copolymers. The purpose of blending is either to
improve processability or to obtain materials suitable for specific needs by tailoring one
or more properties with minimum sacrifice in other properties. The behavior of
polyblends may be expected to depend on the individual properties of the components in
the blend, their relative proportions, degree of heterogeneity and the properties of the
interface between the components. 4everal criteria are used to define the nature of
polyblendsD
Hiscibility or compatibility
9hase diagrams
@elative moduli of the components
The classification also depends on the polyblend method of manufacture =melt,
solution and emulsion mixing>.
7"/ #OMO'ENEIT2 OF B1EN%S
Two polymers are thermodynamically compatible when their free energy of mixing is
negative. Because mixing of two materials is generally endothermic and the entropy of
mixing long polymer chains is small, the free energy of mixing is rarely negative. This is
the reason why blending two polymers usually leads to heterogeneous blend. (f the blend
shows homogenity, then the behavior of the blend behaves as a single polymer.
7"2 #ETERO'ENEOUS B1EN%S
(n this more common category, two polymers are segregated into spatial regions
composed essentially of one or the other pure component. 3sually, the two polymers are
immiscible but they can be compatible. 6onsiderable emphasis is put on the adhesion
between the phases of the blend because it is crucial factor for mechanical properties of
the blend.
7"0 MO%U1I OF T#E COMPONENTS
The theory of modulus tailoring is mainly used in matrix-fibril type of bicomponent
fibers. 6lassification based on the relative moduli of the two components depends to a
great extent on the properties and use of the blends. 8or example, adding of a disperse
phase of higher modulus generally increases the overall modulus and is fre-uently used
to reduce the creep of elastomers. (n contrast, adding of a low modulus polymer in the
blend is generally used to improve the impact resistance and elongation-to-brea, of rigid
plastics.
7"4 R#EO1O'ICA1 ASPECTS OF BICOMPONENT FIBER PRO%UCTION
(t is essential that the viscosities of both polymer fluids are of comparable valueB
otherwise, the higher viscosity component will not tend to rearrange during spinning
causing the distortion of the distribution of the components in the cross section of the
fiber.
6onsiderable attention should be also paid to the rate of solidification of each component.
(t has been shown that during high speed spinning of 99I9<T sheath-core fibers !"# that
the 9<T component achieved higher orientation than would be obtained if the fiber was
ust monocomponent, while 99 component orientation was decreased. This phenomenon
is explained in terms of difference in activation energy of the longitudinal viscosity and
solidification temperature of both polymers.
8" APP1ICATIONS IN NON9O:ENS
Bicomponent fibers made of 99I9< are important material in the nonwoven mar,et. The
main applications includeD
?onwoven fabrics for diapers, feminine care and adult incontinence products =as
top sheet, bac, sheet, leg cuffs, elastic waistband, transfer layers>
Air-laid nonwoven structures are used as absorbent cores in wet wipes
3sed in spun laced nonwoven products li,e medical disposable textiles, filtration
products
REFERENCES
". 1i,utani, (, @adha,rishnan, *., Ari,awa, 4., Ta,a,u, A., 7,ui, ?., *in, ?., ?iwa,
8., 1udo, M.D "High-Speed Melt Spinning of Bicomponent Fibers: Mechanism of
Fiber Structure Development in Poly (ethylene terephtalate!Propylene System",
*.Appl.9ol.4ci. +ol.&2, "%%&, "%";-"%2C
2. 9aul, $.@., 4eymour. ?. "Polymer Blends" vol#$", Academic 9ress, (nc., "%)/
;. "High technology Fibers", part A, 5andboo, of 8iber 4cience and Technology,
vol. (((. <dited by Henachem .ewin and *ac, 9reston, Harcel $e,,er, (nc., "%/:
C. Horgan, $.D "Bicomponent Fibers: Past" Present and Future", 5oechst 6elanese,
6harlotte, ?6, (nda *ournal of ?onwovens @esearch, vol.C, no.C, fall "%%2
:. ($<A %2 <xhibition handouts from 6hisso, *apan and BA48, 34A
&. *effries, @.D "Bicomponent Fibers", Harrow 9ublishing 6o..td. "%)"
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2C. 9apero, 9, +., 1ubu, <., @oldan, ..,D Text.@es.*., ;), /2;, ="%&)>
2:. 9apero, 9, +., 1ubu, <., @oldan, ..,D Text.@es.*., ;), /2;, ="%&)>
2&. www.fitfibers.com