Bicomponent Fibers

Bicomponent Fibers
• Bicomponent fibers are filaments made up of two different
polymers that are extruded from the same spinneret with
both polymers contained within the same filament but
separated by a fine plane. The two polymers differ in
chemical nature or physical properties such as molecular
weight.
Why Bicomponent Fibers?
• The conventional fibers may not have all the desirable
properties. By the use of bicomponent fibers, the
functional properties of both the components can be
exploited in one filament. Further, the fibers can be
produced in any cross-sectional shape or geometry. The
properties of these bicomponent fibers are governed by :

• Nature /properties of two materials

• Their arrangement in the fiber
• Relative proportion of the two
• Thickness of the fiber
Types of Bicomponent Fibers:
• These fibers can be produced in many geometrical arrangements. On the basis
of cross section, these can be classified as

• In addition to these main classes, a wide variety of bicomponent fibers having

different cross-sectional geometries can be produced.
 Functionality Some End-use Applications
Typical Lining clothes, work wear, knitted
Antistatic
Applications: fabrics, underwear
Liquid Sports wear, felt pens, liquid
absorbing absorbers, underwear
• The bicomponent Stockings, beddings, heat
Self-crimping
insulators, knitted fabrics, carpets
fibers can have a Nonwoven fabrics, beddings,
Thermal
range of Bonding
mattresses, printing screens,
functionality and cushions,
Electro- Carpets, seating, work wear,
applications for conductive knitted fabrics
different end- Communication, decoration,
Light-conductive
uses as given telephone
in the table. Enhancement of properties such
as - mechanical properties,
Other
aesthetics, dyeability, water
repellency, flame retardancy
Spinning of Bicomponent Fibers
For proper spinning of two components it is required that:

• Viscosities of the two polymer fluids are comparable. The

viscosity should be high enough to prevent turbulence
after the spinneret.

• Drawabilityof the two polymers should also be

comparable, otherwise splitting may occur.

• Compatibility of both components with the spinning

method that is melt spinning or solution spinning is also
important.
Spinning of Bicomponent Fibers
• The first commercial bicomponent fiber was introduced by DuPont in
the mid 1960s. 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. In the 1970s, various bicomponent fibers
began to be made in Asia, notably in Japan. Very complex and
expensive spin packs were used for manufacturing. These techniques
were found to be technically unsatisfactory and excessively
expensive. Later in 1989, a novel approach was developed using thin
flat plates with holes and grooves to route the polymers. This process
was very flexible and quite price effective.

• These are melt-spun in a specially designed spinning manifold.

Separate extruders and metering pumps are used for both
components. Ratio of the polymers can be controlled by varying the
speed of the metering pumps.
Figure 1. Photograph of a Figure 2. Sketch showing parts of
Bicomponent Spinning Machine Bicomponent Spinning Machine
Core-Sheath Bicomponent Fibers

• In core sheath structure, one of the components called

core is fully surrounded by the second component known
as sheath. In this configuration, different polymers can be
applied as a sheath over a solid core of another polymer,
thus resulting in variety of modified properties while
maintaining the major fiber properties.

Figure 3. Different types of bicomponent

fibers a)-d)Core–sheath, e) Eccentric core-
sheath and f)Multiple core-sheath
Core-Sheath Bi-component Fibers

• Concentricity/eccentricity of the core can be tuned

according to end application. If the product strength is the
major concern, concentric bi-component fibers are used; if
bulkiness is required at the expense of strength, the
eccentric type of the fiber is used.
Applications of Core-Sheath Bi-component Fibers
• Core imparts strength (reinforcing material) and sheath has dye ability,
soil resistance, heat-insulating, and adhesion properties. Some
examples include:
• bonding fibers used in carpets, upholstery etc., where the sheath is
made of PE and core is made of high melting point material like nylon.
• antisoil-antistatic fibers, made using a PET-PEG block copolymer
containing polyester core.
• Sheath can be made from expensive material to increase visual
appearance. And the core can be of low cost material to control cost.
• For making self crimping fibers. Crimp can be controlled by changing
the eccentricity. Eccentricity of core can be varied to balance strength
and bulkiness: used in pillows and furniture.
• In a simple technique to produce core sheath fibers, the two polymer
liquids are separately led to a position very close to the spinneret
orifices and then extruded in a core sheath form as shown in Figure 4.
Figure 4. Technique for Core-Sheath Fiber formation
Core-Sheath Bicomponent Fibers
• In case of concentric fibers the core polymer is in the center of the
spinning orifice outlet and flow of the core polymer fluid is strictly
controlled to maintain the concentricity of both components, while
eccentric fiber production is based on following approaches:

• Eccentric positioning of the inner polymer channel and controlling

of the supply rates of the two component polymers.
• Introducing a stream of single component merging with concentric
sheath-core component just before emerging from the orifice.
• Deformation of spun concentric fiber by passing it over a hot edge.
• Coating of spun fiber by passing through another polymer solution.
• Spinning of core polymer into a coagulation bath containing
aqueous latex of another polymer.