Development Trend And Development Trend Of International Microfiber

superfine

Microfiber varieties have ultra-fine viscose filament and ultra-fine fiber.

Superfine

Super fine polypropylene fiber and so on.

With different technologies, microfibers with different fineness, species and uses can be produced.

Its production technology and manufacturing technology can be roughly divided into direct spinning improvement method, polymer parallel spinning method, stripping composite spinning method, multilayer composite spinning method, blending partition method and island method.

1. direct modified spinning (DSP)

The direct spinning improvement method, also known as the conventional spinning improvement method, refers to the method of directly producing microfiber by using conventional spinning method to improve its technological equipment.

At present, POY or FDY spinning machines can be used to improve microfiber production.

(1) the screw extruder should have a low temperature mixing head (LTM) to ensure the uniformity of the melt.

2. High quality and pure melts containing no gel particles and granular impurities should be provided.

3. Components are required to be installed in order to prevent stack effect and ensure uniform temperature of spinneret components.

In the design of spinneret, attention should be paid to the spacing and arrangement of "no turbulence".

The silk bar should be evenly cooled to reduce the Uster value.

The distance between the spinneret and the side blowing is as short as possible.

The oil feeding system is about 300~600mm below the spinneret.

The spinning channel is shorter than conventional fibers, generally 300~500mm, so as to reduce spinning tension.

We use spindle winding head to spin POY for grooved drum, FDY uses double rotor pverse motion device.

The Silk Road between the heater and the false twist will be straight, otherwise it will cause the filaments and reduce the strength of the fibers.

The friction disc should be made of polyurethane disc to reduce wear on the surface of the fiber.

Using POY and FDY spinning machines to produce microfiber, the greatest advantage is that it can directly obtain single component superfine fibers, and do not need to peel or dissolve two components in the same way as composite spinning or blending silk. It can generally stabilize the production of 0.7~1.0dtex fibers, so the cost is low.

If the melt quality and machine performance are good, the finest to 0.44dtex microfibers can be produced.

If the production of monofilament is lower than 0.44dtex fiber, the compound spinning machine is used.

2. direct optimization spinning (DSOM)

By optimizing the spinning process and improving the traditional spinning method, the viscosity of the polymer, the purity of the melt and the ambient temperature below the spinneret should be reduced, so that the cooling speed will be accelerated and the uniformity of cooling blow will be improved.

By using direct spinning without chemical or mechanical treatment, a single component superfine fiber can be obtained directly, with low production cost and stable product quality.

At present, the finest commercial product made by direct spinning is PET fiber with a single silk density of 0.165dtex.

Compared with conventional spinning method, the spinning method of polyester superfine filament should be optimized as follows:

1. Reduce viscosity of polymer properly.

The goal can be achieved by reducing molecular weight or increasing spinning temperature. These measures can prevent breakage due to droplet extrusion.

2. The spinneret on the spinneret is evenly arranged in the concentric circles of Kong Yingcheng, so that the wire is uniformly cooled.

3. Reduce the ambient temperature below the spinneret, make the wire rapidly cooled, and gather and coil at 20~70cm below the spinneret to obtain the drawn yarn.

The fiber is subjected to 4~6 times of tensile strength.

Under certain conditions, 10~20 times can be stretched, but the technical conditions are unstable and the scope is narrow, so it has not been applied.

Through high precision filtration, the purity of spinning melt can be improved.

Reduce melt extrusion.

This DSOM process has high production efficiency and low cost, which is the main trend of microfiber development.

In Western Europe, the United States mainly uses this technology to produce ultra fine denier fibers.

It is used to imitate silk and make high density fabric (functional clothing).

The most economical method in the POY process is POY directly to the warping machine, that is, WD or WDS, and directly does the super fine shaft.

The Italy ValLesina company has used this technology to produce Microfiber with a filament size of 0.5dtex for silk like warp, but this is suitable for mass production.

3. composite spinning process

The superfine fiber produced by composite spinning machine was first developed in Japan.

Back in 1970, the superfine fiber developed by Dongli company was used for suede.

In 1972, the silk fabric was developed by Chung spinning company. In 1981, the super high density fabric was developed by Zhong spinning company. In the same year, Dongli company developed the second generation of imitation leather products, and in 1985 the bell spinning company developed a high-performance clean cloth.

Microfiber made of composite spinning is divided into two categories: peel type and island type according to different technology.

The stripped microfiber is a composite spinning of two kinds of incompatible polymer melts with similar melt viscosity. After the weaving and dyeing of composite fibers, the microfibers are stripped.

The stripping methods include mechanical method, solvent dissolution method and dissolution method.

Island microfiber is composed of two components, one is sea, the other is island, and the island is distributed in sea components.

It is necessary to select soluble polymers, such as polystyrene, which are woven into fabrics and dissolve sea components with solvents. Leave the island component, and the Microfiber with a filament size of 0.001dtex can be obtained by this method.

The composite spinning process is complex and highly technically demanding. A large number of composite melt streams form a superfine fiber. Not only the special technical design and the complex melt distribution method are needed, but also the spinning components and accessories must be configured correspondingly, and the physical and chemical characteristics of two or more component fibers should be utilized, so that different products can be obtained after weaving.

According to different processes, the composite spinning method can be used to make ultrafine fibers, which are divided into two categories: peel type and island type.

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A. mechanical stripping composite spinning method

The method is to prepare two kinds of polymer melts with different chemical structure and different compatibility but melt viscosity similar to that of composite fibers made of orange peel, rice type and hollow shape in a certain proportion. The superfine fibers are obtained by mechanical peeling with the compatibility of two components and poor interfacial adhesion.

The stripping methods include mechanical method, solvent dissolution method and so on.

The main technology for making superfine fibers in Japan, such as Zhong Fang and di Ren chemical fibre company, is the mechanical peel composite spinning method.

B. Island stripping composite spinning method

Off island composite spinning is also known as "dissolution (or hydrolysis) stripping composite spinning".

This ultrafine composite fiber is a new type of fiber developed in the early 70s. Viewed from the cross section of the fiber, it is a fine and dispersed island component surrounded by another sea component. The sea component and island component are continuous and uniform on the fiber axis, and the resultant composite fibers are dissolved or hydrolyzed to remove the sea component by suitable solvent, so that ultrafine fibers with only island composition can be obtained.

In the early stage, the island composite fiber was composed of PET or PA as the island component. Most marine components were PS or PE, and then the marine components were removed by organic solvents such as benzene and toluene. However, the environmental pollution, flammable and explosive problems were brought to the limit, which limits its development.

Since 90s, people have devoted themselves to the study of water-soluble polyester (COPET), which can be hydrolyzed in hot water or hot lye, which avoids the use of organic solvents and reduces environmental pollution.

At present, there are two main technologies in island composite spinning: "fixed island type" and "indefinite island type".

A. fixed island composite spinning method

The melt distribution system and spinning component of the fixed island method are more complex and the technical requirements are higher than that of the composite spinning method.

The "sea" component and the "island" component are melted by a single screw extruder and then combined to the spinning assembly.

In the spinning process, the islands are not separated from each other, maintaining the shape of monofilament, while the island components are not bonded during the molding process (a good separation of islands and islands between monofilaments).

After the composite spinning, it is found that the core size of the island is surrounded by the core size of the core of the sea component, which is obtained by the conventional fiber size. Only when the "sea" component is dissolved into the core layer of the "island" component, can the superfine fiber be truly made.

(1) according to the experience report of Zhong Fang, Dali, Dongyang and DuPont, Hills, Kulare and other large companies, the island composition is evenly distributed in the length direction of the fiber, and the island is fixed and the fineness is the same, generally only about 0.1~0.05dtex.

At present, island type superfine composite fibers which can produce 980 islands or more islands have been produced.

(2) according to DuPont Co, the polymers currently used for manufacturing island type microfiber are polystyrene polyester, polystyrene polyamide, polyvinyl alcohol polyolefin, etc. the island components in their fibers are PET, PA, PP2 and so on. Marine components are polystyrene, polyethylene (organic solvent soluble), polyester / interphenyl two sodium formate sulfonate copolymer (hot alkali solution soluble) and polyenol (hot water soluble).

For example, the DuPont Co "HPF" product is made of polyester Island composition and polystyrene as the sea component. The fineness of the ultrafine polyester fiber is 0.001dtex, the section is circular and the diameter is 0.1 M.

The whole composite wire can also be processed into fabric, and the sea component can be removed in the post processing, and the micro pores are easy to slip among the fibers. This is especially suitable for artificial leather.

According to the report of Zhong Bo and Dai people in Japan, the fixed island method can freely change the proportion of islands, control the fineness and cross section shape of super fine denier fibers, reduce the cost, reduce the proportion of soluble components, and reduce the amount of dissolution.

4. The company also believes that the soluble polymer must have good thermal stability at the spinning temperature of the polymer. In the spinning process, the two must have a harmonious rheological property. The insoluble polymer is suitable for the price, and the dissolution process should be non polluting, non-toxic and non corrosive.

The technology of island fixing is being developed continuously. For example, the technology of super Island manufacturing of clean glasses, the concavo convex surface of island components, the mixed arrangement of island components and different fibers, and the technology of island mixing with different polymers have been applied in practice.

B. non fixed island composite spinning method

"Non fixed island composite spinning" is also called "polymer parallel spinning."

The technology is obtained through blending of incompatible polymers, and the conventional size is also obtained after spinning.

Unlike the fixed island fiber, the size, quantity, distribution and length of the island in the indefinite island fiber are stochastic in a certain range.

The number of islands is large, so the average line density is smaller. After extracting sea components with solvent, the fibers are fascicular, and the single fiber size is about 0.01~0.001dtex or even 0.0001dtex, so it is more similar to collagen fibers.

(1) according to the reports of Zhong Bo, Tai Ren, Dong Yang and other companies, using Island technology to produce Island fibers, the dependence on the equipment is weaker than that of the fixed Island technology, but it is more complicated to control the technological process.

Such as dispersion and stretching of the sea island components, particle size and distribution, the matching and control of melt viscosity in the spinning process.

These factors directly affect the fiber size, length, quantity, distribution uniformity and separation effect of island components.

(II) experience reports of DuPont, Hills, Kulare and other large companies: the non fixed Island technology uses the non compatible polymer system to blend the silk. Due to the relationship between the composition ratio of the two components and the viscosity ratio of the melt, a component can form a dispersed phase, and another component forms a continuous phase. The dispersed phase is dispersed in the matrix phase by microfibre, that is, the so-called "island" type island blend fiber, and the superfine fiber can be obtained by dissolving or hydrolyzing the sea component.

4. other spinning methods

At present, there are many manufacturing methods for the development of ultrafine staple fiber by international chemical fiber company. Two representative methods are provided for reference.

A. jet spinning (or melt blown)

The method is a row of holes drawn from the end of the knife edge spinneret. The molten polymer is spun out of numerous tiny spinneret holes and is then dispersed by hot air.

Because the method adopts the form of blown polymer, the main body is fine fiber.

But it is also suitable for making thin sheets of short fibers with uneven thickness.

The thin fibers and coarse fibers are simultaneously ejected to make the mixture, and thin sheets with good fluffiness and moisture retention can be obtained.

The disadvantage of this method is that the molecular orientation of the fiber is low.

On this basis, the new method of electrostatic spray spinning, developed by American Al-banyinternational company, is a method of spinning the nanoscale superfine fiber by spraying and stretching in the molding of the polymer solution or melt with the appropriate solution injection and twist parameters.

B. flash spinning

Flash evaporation is a kind of spunbond, which belongs to solution spinning.

The spinning method is to dissolve the polymer in low boiling solvents (such as liquefied petroleum gas), and heat and pressurize it to produce fibers from instant spout.

This instantaneous high-pressure jet polymer can reach 10 thousand meters per minute, and the diameter of the fibers is generally between 0.1 m~10 and m, and 0.01dtex ultrafine fibers can be obtained.

Therefore, some people call flash flash process "flash spinning" or "quick spinning". The demand for nonwovens is growing rapidly, and can be used in various packaging materials such as decorative materials and envelopes.

In addition, adding antistatic agent, pparent pigment and using ultrasonic bonding technology in polyethylene is a major trend of DuPont Co's flash spinning.

Other spinning methods include centrifugal spinning, turbulent forming, gel spinning, fibrin refining, ultra high speed drafting, and turbulent forming.

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New technology and products of microfiber

Microfiber is known as the new generation of synthetic fiber. It is a high performance, high quality and high-grade textile material. It is a typical representative of the new synthetic fiber developed by chemical fiber in the direction of high technology and high simulation.

The world's major chemical fiber companies are competing to develop new technologies and products for microfiber (NT/NP):

NT/NP-1 and "regenerate" microfibers.

Based on the super soft water repellency microfiber "Primaloft", Al banyinternational has developed a new superfine fiber "PrimaLoftRegenerate" with better performance.

The fiber is made of ultrafine fibers of 0.2 * 0.05~0.001dtex diameter, made of over 50% recycled materials and patented microfiber. Combined with microfiber and patented special processing procedures, it achieves incredibly soft, light weight and water repellent properties.

It also accords with the strict testing standard. Its features are high heat preservation effect, quick drying performance, light weight, good air permeability, soft handle, good porosity and good water repellency.

Its water absorbency is 1/3 of general fiber, and its heat preservation effect is 14% when it is dry, and its temperature is 24% when it is moist.

NT/NP-2, "Super clean" microfiber.

South Korea's SilverSta recently developed a new superfine fiber fabric called "Super clean". Because of its super cleaning ability, it does not need to use chemical cleaners when washing, and its products are very popular in the market.

The material of Super clean is made of PET, PA and PA6, and is made by fission and decomposition. The fineness of the fiber is 1/20 of silk and 1/360 of hair.

Another feature of the microfiber is the use of Orange flap technology to separate the filament into multi flaps in the filaments. It increases the surface area of the fiber and increases the porosity in the fabric. With the capillary core absorption effect, the water absorption ability is strong and durable, and it can be washed about 600 times.

The special cross section can capture more than a few microns of dust particles more effectively, and the effect of removing dirt and removing oil is very obvious.

NT/NP-3, "Beli -effect" microfiber.

Japanese bell spinning company's "Beli -effect" is a cationic dyeable composite polyester superfine fiber.

Beli -effect is a new superfine fiber developed from the original 70% polyester /30% nylon blended "Belimax", modified polypropylene and polyester parts.

Beli -effect used 24 valve split spunlace technology to open the fiber. After stripping, the filament fineness was 0.1dtex~0.05dtex, and the fiber opening rate was above 80%.

Beli -effect is a high shrinkage and high density fabric, so its products have good softness, elasticity and fluffiness. The main uses include jackets, blouses, jackets, seat covers, bags, shoes and so on.

NT/NP-4, "Trevor biyou" microfiber.

The newly developed "Trevor biyou" superfine silk fiber new product developed by Xuyi Yicheng company uses the "RCT technology" to mix polyester / polyester together, so that the ratio and shape of the two polymers are controlled to be irregular. When the polymer is dissolved in a solvent, the remaining polymer filament fineness is 0.1dtex~0.01dtex, and its shape is still irregular.

The fabric made of Trevor biyou microfiber has a complex concave and convex shape, which produces fine irregular diffuse reflection, showing different luster of different angles. It is comfortable to wear and adopts the technology of different shrinkage and blending. The handle is good and full, and is suitable for blouses, tuxedo and so on.

NT/NP-5 and "WSLR" microfibers.

The "WSLR" produced by Dongli company is a silk like Microfiber with a silk effect.

WSLR uses the polymer "potential multistage high shrinkage" technology, and the filament fineness of the fiber can reach 0.11 dtex after high pressure spunlace.

At the same time, the "multi petal shaped section" technology is used to engrave 0.1 M grooves on each top of the three petals, which can capture the visible light of 0.4~0.8Fm, so its product has good chromaticity and produces "Silk sounding" through the friction between the slots. The product is mainly used for women's smock, suits and eggshells.

NT/NP-6 and "RominaIII" microfibers.

The "RominaIII" microfiber developed by the company is a 0.01~0.05dtex microfiber made from two materials of modified polypropylene / polyester.

The innovative technology is to make use of a silk thread when spinning: that is, in the micro cell, the filament has the difference of filament length and complex structure function, thus forming a complex multi-layered structure of the microfiber, which has the concave convex and the silk loop velvet effect, so that the fabric has the natural style of synthetic fiber, that is, smooth and bulky, and has soft and thin handle, which is inferior to natural fiber.

NT/NP-7, "Natural light" microfiber.

The "Natural light" microfiber, developed recently by Shaw industries, is a blend two component composite fiber made of polystyrene as sea component and polyester as island component.

When Natural light was used as a new generation of base material for artificial leather, needle punched nonwovens were first made. After dissolving polystyrene, it became a microfiber with a filament size of 0.00011dtex.

Natural light also adopted the new technology of Cut down, thus changing the products with natural luster on the fiber section. This new section reflects the luster different from the traditional polyester fiber and reduces the brightness of the product to make it closer to the natural luster.

DuPont Co clothing department manager Tonya Farrow disclosed.

Natural light will be widely used in trousers, skirts and other garments, and has great competitiveness in the market potential.

NT/NP-8, "Super Beaver" microfiber.

A new type of breathable and waterproof microfiber "Super Beaver" developed by Hills, USA, is an orange peel superfine fiber separated from two polymers of nylon / polyester, with a fineness of 0.01 dtex~0.001 dtex.

The key technology is to use the technology of "different stripe oblique cutting" in the splitting of fibers, so as to make the structure of pores and intercellular filaments on the cell wall to pport and circulate the water and other substances between cells, so as to have the structure of super sea ape.

After its weaving process, the superfine fiber has irregular bending on the fabric, which is very fine. It prevents external water droplets and can discharge sweat. It can be used in swimsuits, outdoor clothing and other products.

NT/NP-9 and "Thermostat" microfibers.

The new "Thermostat" microfiber developed by the United States of America has the fineness of 0.01 dtex~0.005 dtex.

Thermostat is a kind of special-shaped section memory type suitable temperature fiber.

Its technology is to use polymer synthesis and modification technology, to make polycondensation of polyisoprene materials and molecular structure adjustment to make automatic tempering chemical fibers. It will be sensitive to the temperature response around, and can change with the temperature changes, so that a small climate environment can be formed in clothing.

In the heat of summer, the special section of the fiber is contracted automatically, so that the hole of the fabric is opened and ventilated and breathed, which greatly improves the heat dissipation ability of the garment. In winter, the profiled section of the fabric expands itself, so that the hole of the fabric is closed and the air circulation is blocked, thus improving the clothing's heat retention ability.

NT/NP-10 and "SABK" microfibers.

Inspired by the wing structure of Butterfly King of South America, the company developed a dark effect microfiber called "SABK".

In order to explore the dazzling color effect of butterfly wings in South America, the company studied the color change and luster of butterfly wings due to light interference, and made use of composite spinning technology to combine the polyester with different thermal shrinkage. The superfine fibers with camber characteristics were twisted together, and their fineness was 0.05 dtex~0.001 dtex, so that the dark effect fiber had the same microscopic color effect as the Butterfly King of South America.

Development trend and development trend of microfiber

Microfiber is a breakthrough in the development of chemical fibers. Its development has brought the textile industry "epoch-making" new products.

With the rapid development of the global economy, energy crisis and environmental pollution are attracting more and more attention.

How to maintain the sustainable development of economy is a problem that needs to be solved urgently. However, the continuous development of microfiber and the increasing development of microfiber materials in conventional and high-performance products will continue to enter more new applications.

According to the latest forecast report of USTIA, the development of microfiber materials is closely related to the development of society, economy, resources and environment, so new growth points and crossover points will continue to emerge. This not only promotes the development of microfiber, but also enriches the connotation of new material science.

Its development trend and development trend are as follows:

One is the replacement of ecological restoration.

After entering the twenty-first Century, all countries in the world increased the intensity of environmental protection, and implemented measures such as returning farmland to forests, returning grazing to grass, and so on.

In this situation, one is to make up for the shortage of natural leather, the two is to meet people's higher level needs. Microfiber synthetic leather is gradually used instead of a part of genuine leather.

In some countries and regions such as Japan, the development of technology has made the microfiber synthetic leather have replaced the natural skin with insufficient resources. The decoration of bags, garments, shoes and vehicles and furniture made of synthetic leather and synthetic leather has also been increasingly recognized by the market.

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Two, the scope of R & D is expanding.

In the future, microfiber materials research and related disciplines are constantly intersecting and infiltrating. New discipline growth points are emerging. It has penetrated into the fields of materials science, energy science and composite materials from the traditional chemical fiber discipline and its related physical and chemical disciplines.

Three, we should pay more attention to environmental protection.

In the long term evolution of natural organisms, the most stable components of microstructures have been obtained by using the simplest components and the most common conditions. People can be inspired by this micro hierarchical structure, and prepare superfine fibers and composites with superior properties through bionics or biomimetic design, and give full play to the advantages of renewable and biodegradable microfiber, especially saving, reducing consumption and lowering energy.

Four, we should pay more attention to the basic and functional design.

The most important feature of superfine fiber is its excellent basic properties and functions. In the future, the research and development of microfiber and its materials not only focus on the improvement of their basic properties, but also focus on giving them new functions, focusing on the combination, high performance and functionalization.

The five is the industrial use of the third boom.

The development of microfiber will definitely be developed in all industrial fields in the future.

This leading high-tech fiber will become an important material.

It is estimated that if the third boom is coming, the emphasis will be on industrial uses.

The continuous pursuit of high function and multi-function in the field of industry and decoration will become the driving force for the continuous development and research of microfiber products.

It is expected that in the near future, microfiber products will be widely used in industry, agriculture, aerospace, marine and other fields.

The six is the leading product in the field of clothing.

For modern clothing, it has entered an era of material wins. The development of new microfiber fabrics can greatly increase the added value of garments.

Paying attention to the development of science and technology fiber, grasping its characteristics and realizing the new and top-grade technology of fabrics will become a breakthrough in the field of textile products.

Compared with ordinary fibers, ultrafine fibers have the advantages of softness, Hikaruzawa Youwa, strong fabric coverage and good physiological effects.

The continuous pursuit of new quality, new style and new functions in the field of fiber is bound to be one of the leading products of the "new synthetic fiber".