Journal of Textile Research ›› 2024, Vol. 45 ›› Issue (08): 54-64.doi: 10.13475/j.fzxb.20240400402

• Academic Salon Column for New Insight of Textile Science and Technology: Advanced Nonwovens and Technology • Previous Articles     Next Articles

Research progress in melt spinning technology for bicomponent microfibers

DUO Yongchao1, SONG Bing1, ZHANG Ruquan2, XU Qiuge1, QIAN Xiaoming1()   

  1. 1. School of Textile Science and Engineering, Tiangong University, Tianjin 300387, China
    2. College of Textile Science and Engineering, Wuhan Textile University, Wuhan, Hubei 430200, China
  • Received:2024-04-01 Revised:2024-04-26 Online:2024-08-15 Published:2024-08-21
  • Contact: QIAN Xiaoming E-mail:qxm@tiangong.edu.cn

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Abstract:

Significance Microfiber materials, as a strategic emerging material, play an indispensable role in national economic and social development, constituting a focal point of global competition within the textile industry. Exhibiting characteristics such as low fiber linear density, low bending stiffness, large specific surface area, adsorption capability, and strong capillary effects, microfibers find widespread applications in fields including medical hygiene, personal protection, environmental sustainability, energy conservation, clothing, and home textiles. In the fabrication processes of microfibers, nonwovens produced via methods such as melt blowing, flash evaporation, and electrospinning exhibit relatively low strength, limiting their usage to filtration and medical protective applications. While direct melt spinning offers lower production costs, stringent process requirements often hinder the attainment of high-quality microfibers. In the realm of composite spinning, the production of microfiber materials involves the utilization of physical or chemical methods to achieve the formation of bicomponent composite fibers. This method is characterized by its high speed, efficiency, and productivity, making it one of the most effective techniques for mass-producing high-strength microfiber materials.

Progress This paper provides an overview of the forming processes, polymer properties, and technical requisites involved in the production of microfibers through composite spinning. It elaborates on the polymer selection, fiber formation mechanisms, and distinctive traits of sea-island and split composite fibers. Moreover, it delves into the principles of fiber precursor formation using chemical and physical methods, discussing the merits and drawbacks of the processes. Furthermore, based on these characteristics, it analyzes the selection of different composite fiber polymers and the trends in process development both domestically and internationally. It examines their impact on the production of microfibers and nonwoven materials. The application domains of melt composite fibers for microfibers material production are summarized, and future directions for the development of composite fiber production for microfibers are proposed.

Conclusion and Prospect The preparation of microfibers nonwovens through biocomponent composite spinning holds vast potential applications in synthetic leather base, medical hygiene, precision filtration, apparel, and various other fields. These materials have been widely produced and employed in numerous applications. With the emergence of green concepts such as carbon neutrality and energy conservation, the development of efficient and eco-friendly fiber spinning technologies, such as low-energy consumption (split fiber easy-splitting technology) and chemical-free methods (thermoplastic polyvinyl alcohol, water-soluble polyester composite spinning), represents the future direction of composite fiber production for microfibers. Additionally, as nonwoven technology continues to advance and interdisciplinary concepts gain traction, composite fibers are poised to achieve further refinement in fiber morphology through shaping techniques, functionalization through advanced finishing technologies, and product greening through material-process integration, thus better serving society.

Key words: bicomponent fiber, microfiber, composite spinning, sea-island fiber, split fiber, splitting technology

CLC Number: 

  • TS174.8

Fig.1

Schematic diagram of co-blended spinning"

Fig.2

Schematic diagram of composite fiber cross-section. (a) Indefinite-island-fiber cross-section; (b) Fixed-island- fiber cross-section; (c) Split-fiber cross-section"

Fig.3

Schematic diagram of conjugate spinning"

Fig.4

Micro-morphology of TPVA/PA composite fiber. (a) 32-petal segmented-pie fiber; (b) 16-island sea-island fiber; (c) 32-petal segmented-pie water-soluble split fiber; (d) 16-island sea-island fiber water-soluble split fiber"

Fig.5

Influence of water dissolution time and temperature on splitting of composite fiber"

Fig.6

Composite fiber splitting mechanism"

Fig.7

SEM images of segmented-pie composite fibers. (a) "Evolon" microscopic morphology; (b) 8+8 hollow segmented-pie; (c) 16+16 hollow segmented-pie"

Fig.8

Bicomponent spunbond spunlace process flow diagram"

Fig.9

Microscopic morphology of nonwoven fabrics before (a) and after (b) fiber splitting (×1 000)"

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