Novel fibers, high airtightness fabrics and a fabrication method thereof

Abstract

The present invention provides a new tetragon fiber and a method for fabricating the same. The present invention includes: heating a thermoplastic material, extruding it from a tetragon-shaped nozzle, passing it through an airless zone, then cooling and solidifying to form threadlike substances, rolling up then processing the threadlike substances to form fibers with tetragon cross sections. The fabrics of present invention comprises a property of fine air-tightness.

1 . A fiber of tetragonal cross section, which is partially oriented yarn (POY), fully oriented yarn (FOY) or spin draw yarn (SDY).  
     
     
         2 . The fiber of  claim 1 , wherein said tetragon fiber is a rectangle fiber.  
     
     
         3 . The fiber of  claim 2 , wherein said rectangle fiber is a square fiber.  
     
     
         4 . The fiber of  claim 1 , wherein a ratio of the long to the short side of said fiber is in the range of 1.0-2.0  
     
     
         5 . The fiber of  claim 1 , wherein said fiber material is a thermoplastic polymer.  
     
     
         6 . The fiber of  claim 5 , wherein said thermoplastic polymer comprises polyamide resin, polyester, polyolefin, a copolymer or a mixture thereof.  
     
     
         7 . The fiber of  claim 6 , wherein said polyamide resin comprises Nylon 6, Nylon 11, Nylon 12, Nylon 46, Nylon 66, Nylon 610, Nylon 612, a copolymer or a mixture thereof.  
     
     
         8 . The fiber of  claim 6 , wherein said polyester is polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), other aromatic and aliphatic polyesters, a copolymer or a mixture thereof.  
     
     
         9 . The fiber of  claim 6 , wherein said polyolefin is polyethyelene (PE), polypropylene (PP), Polybutylene, a copolymer or a mixture thereof.  
     
     
         10 . A method of fabricating the fiber of  claim 1 , comprising the steps of: 
 melting a fiber material, which is a kind of thermoplastic polymer;    extruding said molten polymer from a special contoured nozzle and then passing said molten polymer through an air-blocked zone to form molten filaments;    solidifying said molten filaments to form solid filaments; and    drawing said solid filaments to form fibers with tetragonal cross sections; the    distance of the air-blocked zone ranges from 0.1 to 15 cm; and    the ratio of length vs. width of said tetragonal cross section is 1.0-2.0.    
     
     
         11 . The method of  claim 10 , wherein said distance of air-blocked zone is in the range of 0.1 to 15 cm.  
     
     
         12 . The method of  claim 10 , wherein said fiber material is melted by heating at a temperature of 180-320° C.  
     
     
         13 . The method of  claim 10 , wherein said molten filament is cooled and solidified by quenching air.  
     
     
         14 . The method of  claim 13 , wherein said quenching air is blown at a speed of 0.1-1.5 m/sec.  
     
     
         15 . The method of  claim 10 , wherein said drawing method is performed by feeding solidified filaments into a heated roller set with rollers operating at differential speeds to effect drawing.  
     
     
         16 . The method of  claim 15 , wherein said roller set provides a draw ratio bf 1-8.  
     
     
         17 . The method of  claim 10 , wherein the drawing tension is 0.01-1.0 g/d.  
     
     
         18 . The method of  claim 10 , wherein the winding speed is 2000-8000 m/min.  
     
     
         19 . A fabric prepared by said tetragon fiber of  claim 1 .  
     
     
         20 . The fabric of  claim 19 , wherein the warp and the weft fibers of said fabric are composed consisted of monofilament fibers or multifilament fibers with different warp and weft directions.  
     
     
         21 . The fabric of  claim 19 , wherein said fabric comprises a density of warp and weft in 10-500 thread/inch.  
     
     
         22 . The fabric of  claim 19 , wherein the air permeability of said fabric is 0.01-1.5 cc/cm 2  ·sec.  
     
     
         23 . The fabric of  claim 19 , wherein said fabric comprises a structure of woven, knit or non-woven.