WO2006033118A1

WO2006033118A1 - A synthetic fiber, a device and a method for manufacturing the same and fabric made from the same

Info

Publication number: WO2006033118A1
Application number: PCT/IN2005/000321
Authority: WO
Inventors: Saurabh S. Patwa
Original assignee: Patwa Saurabh S
Priority date: 2004-09-21
Filing date: 2005-09-21
Publication date: 2006-03-30
Also published as: WO2006033118B1

Abstract

The present invention provides a synthetic fiber capable of providing cotton-type effect, device and method of manufacturing the same and a fabric spun from the synthetic fiber. The synthetic fiber is a hollow/multi-hollow synthetic fiber having pores/perforations on the surface of said hollow fiber that allows better aeration through the fiber and retaining of water/fluid in the hollow portion of the said fiber. The fiber is monofilament synthetic fiber or staple synthetic fiber. Further, the fiber is spun fiber or a composite fiber. The fabric spun from the fiber absorbs perspirations in contact with the fiber. The cloths made from the fabric are comfortable as fibers absorbs perspiration and also provides aeration thereby provides cotton-like effect.

Description

TITLE

A SYNTHEC FIBER, A DEVICE AND A METHOD FOR MANUFACTURING THE SAME AND FABRIC MADE FROM THE SAME.

FIELD OF INVENTION

The present invention relates to the fibers more particularly to the synthetic fibers and fabric made from the same.

BACKGROUND OF THE INVENTION

Cotton fabrics have good breathing and absorption properties because of which, cotton fabrics absorb perspiration excreted during different conditions such as hot/ humid atmosphere, working in office, playing sports, doing hard work jobs etc that provides a cooling effect (Defining the same as cotton type effect). However, cloths made of cotton are expensive because of higher price of the cotton and increasing demand for the cotton day by day. Further, cloths made of the cotton take more time to dry in rainy seasons or humid atmosphere and start stinking and decaying.

Therefore, now a day to meet the demand of the cotton, synthetic fibers including polyester fibers, acrylic, polypropylene etc are used alone or mix in the cotton for making synthetic textiles. However, clothes made of polyester fibers and other synthetic fibers do not absorb/retain water like cotton fibers i.e. do not provide cotton type effect and therefore, are generally considered less comfortable than cotton fibers.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a synthetic fiber capable of providing cotton-type effect. Further object of the present invention is to provide a device and method for manufacturing said synthetic fiber.

Another object of the present invention is to provide a synthetic fiber that obviates disadvantages of the prior arts.

According to the first aspect of the present invention, a synthetic fiber capable of providing cotton-type effect is a hollow/multi-hollow synthetic fiber having pores/perforations on the surface of said hollow fiber that allows better aeration through the fiber and retaining of water/fluid in the hollow portion of the said fiber.

The pores/perforations are micro openings of oval, star, round, square, triangular or any other desired profile having equivalent diameter between 0.1μm and 40μm preferably between 0.1μm and 10μm. The total area of the pores on the fiber is between 5% and 70% of surface area of the said- fiber preferably between 20% and 60% depending upon the application of the fiber.

The outer diameter of the cotton-like fiber is from 0.5μm to 40μm and wall

thickness of the cotton-like fiber is 0.1 - 5μm. Preferable outer diameter of the fiber is 10-20 μm and wall thickness is 0.3-3μm.

The synthetic fiber of the first aspect of the present invention is a continuous synthetic fiber or a staple synthetic fiber having length between 1 mm and 250mm.

Further, the synthetic fiber of the first aspect of the present invention is spun fiber manufactured by spinning hollow perforated staple fibers.

Moreover, the synthetic fiber of the first embodiment is a composite fiber manufactured by spinning hollow staple synthetic fibers with the other synthetic staple fibers or natural fibers. The natural fibers are wool fibers, cotton fibers or the like.

Further, the synthetic fiber have oval, round, star, circular or of any desired cross-section.

Said fiber is made at least one of polymer or synthetic materials including polyester, polypropylene, nylon, acrylic, carbon, high density molecules or the like.

According to the second aspect of the present invention, a device for manufacturing synthetic fiber comprises a extruder for producing hollow fiber and a punch adapted on or after the extruder wherein said punch forms pore/perforations randomly or in desired pattern on extruded hollow fiber to produce a synthetic fiber according to the first aspect of the present invention. Further, a cutter is adapted after said punch to cut the cotton-like fiber to produce staple synthetic fibers according to the present invention. Said punch is be a mechanically operating punch/or a laser operated punch operating in timely fashion to punch the hollow fiber.

According to the third aspect of the present invention, a method for manufacturing cotton-like synthetic fibers comprising steps of melting polymer chips, extruding the hollow fibers and simultaneously punching pores radially in random or desired pattern to obtain monofilament cotton- like synthetic fiber. The monofilament cotton-like fiber is cut to obtain staple fibers and spinning alone or with the natural fibers or staple polymer fibers to produce a spun fiber or a composite fiber.

According to the fourth aspect of the present invention, a fabric weaved from the synthetic fiber according to the first aspect of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

Fig 1 is a magnified view of a synthetic fiber according to the present invention.

Fig 2 is a magnified view of a fabric made of a monofilament synthetic fiber according to the present invention.

Fig 3 is a magnified view of a fabric comprising a composite synthetic fiber according to the present invention.

Fig 4 is a device for manufacturing synthetic fiber according to the present invention.

Fig 5 is a flow chart of the method of manufacturing the synthetic fibers according to the present invention.

Fig 6A is a graph of water absorbency of the fiber according to the present invention compare with cotton and normal polyester fiber.

Fig 6B is a graph of water absorbency of the fiber according to the present invention compare with cotton and normal polyester fiber.

Fig 6C is a graph of water absorbency of the fiber according to the present invention compare with cotton and normal polyester fiber.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The synthetic fiber (10) as shown in the Fig 1 according to the first aspect of the present invention is a hollow synthetic fiber having pores (6) on the surface (2).

The pores/perforations (6) are micro openings of oval, star, round, square, triangular or any other desired profile having equivalent diameter between 0.1 μm and 40μm preferably between 0.1 μm and 10μm. The total area occupied by the pores (6) is between 5% and 70% of surface area of the fiber preferably between the 20% and 60% of the surface area of the fiber. However, the area of the pores depends upon number and the diameter of the pores (6) provided on the synthetic fiber. Further, the number or flux of the pores/perforations (6) depends on the application of the fibers for example towels, napkins, underwear and the like require more number or flux of pores having large diameter upto 40 μm to retain more water.

The fiber (10) has diameter between 0.5 μm and 40 μm and having wall thickness between 0.1 μm and 5μm depending upon the applications of the fiber. Preferable diameter of the fiber is 10-20 μm and wall thickness is between 0.3 and 3 μm.

The pores/perforations (6) on the synthetic fiber (10) allows liquid/water in contact with the fiber (10) enters through the pores/perforations (6) (hereinafter referred as pores only) and rises in the hollow portion (8) of the fiber (10) and retains in the hollow portion (8) of the said fiber by the capillary effect and the pores that are not in contact with the water/liquid provide better aeration through the fiber (10), the fluid in the fiber (10) from the pores (6) fiber in the form of vapor providing a cotton-like effect. Therefore, the synthetic fiber (10) dries sooner.

The synthetic fiber (10) according to the present invention is a monofilament as shown in Fig 2. The staple synthetic fiber of the present invention is manufactured by cutting the monofilament fiber of the present invention of required length. Generally, the length of the staple fiber is 1- 250mm. The fiber (10) is manufactured by spinning staple synthetic fibers having pores/perforations (6). Further, staple synthetic fibers (12) are mixed with the natural or synthetic fibers (14) and spun together to obtain a composite synthetic fiber (310) as shown in fig 3 according to the present invention as shown in Fig 3. The natural fiber used in the composite synthetic fiber is cotton fiber, wool fiber or the like. The percentage of the mixing of the staple synthetic fiber in natural fibers or staple synthetic fibers depends upon the applications of the fabric. The said staple fibers or mixed fibers can be spun together by using conventional spinning machines such as ring spinning machines/open-end spinning machines to obtain a synthetic fiber (10).

The fibers having oval, round, star or of any desired cross-section of the can be easily manufactured. Further, the cotton-like fibers having any color can be easily manufactured.

A device (100) for manufacturing the monofilament synthetic fiber or staple fibers according to the present invention is shown in Fig 4. The device (100) comprises a conventional extruder (120) for extruding hollow synthetic fiber is connected to the polymer chip unit and molten dosing unit (110) for supplying molten polymer and at least one punch (130) adapted on or after the extruder (120) for punching the hollow fiber. The hollow punched fibers then pass through the spinning beam, heating and cooling arrangement (150) and winded on the bobbin as monofilament synthetic fiber. Further, a cutter (not shown) is adapted after the punch (130) to cut the monofilament fibers (10) into the staple synthetic fibers. The punch (130) according to the present invention is a laser operated punching machine. The laser operated punching machine (130) still as shown in Fig 4 or rotates around central axis of the extruded hollow fiber (4) and emits laser beams (135) in random fashion or in desired pattern and the required diameter on the hollow fiber (4) and punches the perforations (6) on the hollow synthetic fiber. Alternatively, many number of the laser operated machines may be mounted surrounding the central axis of the hollow fiber emitting laser beams toward the hollow fiber for punching pores (6) on the hollow fiber (4). The laser operated punching machine works similar to the laser machine use in the cataract eye surgery. Further, punch is a mechanically operated punching machine (not shown).

The present invention provides a method for manufacturing a synthetic shown in Fig 5. The method comprises steps of melting resins/chips of polymer and extruding a hollow fiber using a conventional extruding machine and then punching perforations on the hollow fibers to obtain a perforated monofilament synthetic fiber according to the first aspect of the present invention and spinning the cotton-like synthetic fiber. Further, said monofilament fibers are cut into the staple fibers and is spun alone or in combination with natural or synthetic staple fibers to obtain the cotton-like synthetic fiber.

The magnified fabrics 200 and 300 weaved from the monofilament synthetic fiber (210) and composite synthetic fibers (310) are shown in Fig

2 and 3 respectively.

The fabric made of the synthetic fiber absorb perspirations excreted by capillary effect and allows the perspiration to escape through the fiber in the form of vapors thereby providing a cooling effect like cotton. Also if the fibers of the fabric get squeezed, the air in the fiber moves out of the fiber through the pores creating a vacuum that helps to absorb perspirations excreted. Further, the fabric cloths made of the synthetic fiber have longer life, durable, cost effective and cloths made from the fabric are comfortable to wear in any seasons i.e. rainy, summer and winter and also easily get dry in any season or humid atmosphere without stinking.

The fabric made of the cotton-like fiber can be used to manufacture sport wear, formal dresses, casual wear, athletic wear, socks, towels, napkins, suiting and shirting, undergarments, bed sheets, curtains, pillows/bed as filler fibers, rugs/bullet proof layers, nappies and the like.

Fig 5A, 5B, and 5C shows the graphical test results of the synthetic fiber in comparison with the cotton and normal polyester. The details of the synthetic fiber used for test are as follows:

Test i:

10 gm of cotton fibers, polyester fibers and the staple synthetic fibers are dipped in the 13 gm water and time required for absorbing water calculated in second. The graph is plotted for the time required to absorb 13 gm water for each fiber as shown in Fig 6A. The result of this test shows the time required to the synthetic fiber is substantially equal to the cotton and substantially less than the polyester fiber. Test 2:

In this test method the dry sample of the cotton-like synthetic fiber, cotton fiber and polyester fiber dipped in water for 10 minute allowing absorption of water and a graph is plotted for absorption length for each fiber as shown in Fig 6B. The absorption length for the synthetic fiber is above 140 mm and is substantially greater than the cotton (85mm) and polyester fiber (55mmm). This test proves that the invented synthetic fiber absorbs more water as compare to the cotton fibers and polyester fibers.

Test 3:

This test is conducted to compare the time required to dry for the cotton- like synthetic fiber, cotton fiber and polyester fiber. In this test, the fibers wetted with 100 gm water were dried in a drier at about 40⁰C and a graph is plotted for time elapsed v/s weight of the water in the fibers as shown in Fig 6C. This test proved that the synthetic fiber requires substantially less time to dry as compare to the cotton and polyester fibers.

The above test proves that the synthetic fiber have better absorbing properties and dry sooner than the cotton fibers and normal synthetic fibers. Further, the cotton-like fibers dry fast as compare to the cotton fibers and polyester fibers.

The aspects herein described are only intended to be examples of preferred aspects of the invention. The description is intended to incorporate all variations and adaptations having the same results as the aspects herein described.

Claims

1. A synthetic fiber capable of providing cotton-type effect characterized in that said synthetic fiber is a hollow/multi-hollow synthetic fiber having pores/perforations on the surface of said hollow fiber that allows better aeration through the fiber and retaining of water/fluid in the hollow portion of the said fiber.

2. A synthetic fiber as claimed in claim 1 wherein said pores/perforations are micro openings of oval, star, round, square, triangular or any other desired profile having equivalent diameter between 0.1 μm and 40μm preferably between 0.1 μm and 10μm.

3. A synthetic fiber as claimed in the claim 1 wherein the total area of the pores is between 5% and 70% of surface area of the said fiber preferably between 20% and 60%.

4. A synthetic fiber as claimed in the claim 1 wherein said fiber have diameter between 0.5μm and 40μm.

5. A synthetic fiber as claimed in claim 1 wherein said fiber has wall thickness between 0.1 and 5μm.

6. A synthetic fiber as claimed in claims 1-4 wherein said fiber is a monofilament synthetic fiber.

7. A synthetic fiber as claimed in claims 1-4 wherein said fiber is a staple fiber having length between 1 mm and 250 mm.

8. A synthetic fiber as claimed in claim 1-4 wherein said fiber is a spun fiber produced by spinning said staple fibers.

9. A synthetic fiber as claimed in claim 1-4 wherein said fiber is a composite fiber produced by spinning staple fibers with the natural fibers or staple polymer fibers.

10. A synthetic fiber as claimed in claim 9 wherein said natural fiber is a cotton fibers, wool fibers or the like

11. A synthetic fiber as claimed in preceding claims wherein the synthetic fiber have oval, round, star, circular or any desired cross section.

12. A synthetic fiber as claimed in preceding claims wherein said cotton-like fiber is made of polymer or synthetic materials including polyester, polypropylene, nylon, acrylic, carbon, high density molecules or the like.

13. A device for manufacturing a synthetic fiber comprises a extruder for producing hollow fiber and a punch adapted on the hollow fiber adapted on or after the extruder wherein said punch forms pores/perforations on the extruded hollow fiber to obtain cotton-like synthetic fiber.

14. A device as claimed in claim 13 further comprises a cutter to cut the fiber to produce staple synthetic fibers.

15. A device as claimed in claim 14 wherein said punch is a mechanically operating punch/ or laser operated punch.

16. A method for preparing synthetic fibers as claimed in claim 1 comprising steps of extruding the hollow fibers and punching pores radially to obtain monofilament synthetic fiber.

17. A method as claimed in claim 15 further comprises step of cutting the fiber to obtain staple fibers and spinning alone or with the natural fibers or staple polymer fibers to produce a spun fiber or a composite fiber.

18. A synthetic fabric weaved from the synthetic fiber as claimed in claims 1-9.