Composite fiber having a high surface area and flexibility and method for manufacturing the same, and substrate containing the composite fiber and method for manufacturing the same

Abstract

The present invention provides a composite fiber having a high surface area and flexibility and a method for manufacturing the same, and a substrate containing the composite fiber and a method for manufacturing the same. The composite fiber contains a first component and a second component, and has a maximum diameter and a circumference. The first component has a central portion and a plurality of extension portions. A maximum length of the central portion is less than three quarters of the maximum diameter. The first component is in an amount of 50 wt % to 95 wt %, based on the total weight of the composite fiber. The second component has a plurality of outer portions disposed between two extension portions, and the second component is in an amount of 5 wt % to 50 wt %, based on the total weight of the composite fiber.

What is claimed is: 
     
         1 . A composite fiber having a high surface area and flexibility, having a cross section in a substantially circular shape, and having a maximum diameter and a circumference, the composite fiber comprising:
 a first component, having a central portion and a plurality of extension portions extending from the central portion to the circumference, wherein the maximum length of the central portion is less than three quarters of the maximum diameter, and the first component is in an amount of 50 wt % to 95 wt %, based on the total weight of the composite fiber; and   a second component, having a plurality of outer portions, wherein each outer portion is in a fan shape and is disposed between two extension portions, the extension portions and the outer portions are alternately distributed in the circumference, and the second component is in an amount of 5 wt % to 50 wt %, based on the total weight of the composite fiber.   
     
     
         2 . The composite fiber according to  claim 1 , wherein the material of the first component is a polyester polymer, polyamide polymer or polyolefin polymer, the material of the second component is nylon or a polyolefin polymer, and the maximum length of the central portion is greater than one-eighth of the maximum diameter. 
     
     
         3 . The composite fiber according to  claim 1 , wherein each extension portion has a first end and a second end, the first end is close to the central portion, the second end is close to the circumference, the width of the second end is greater than the width of the first end, and the extension portions are in a fan shape or a water drop shape. 
     
     
         4 . A method for manufacturing a composite fiber having a high surface area and flexibility, comprising:
 (a) providing a first component, wherein the first component has a first viscosity;   (b) melting the first component, transferring the melted first component to a spin beam, and setting a first temperature;   (c) providing a second component, wherein the second component has a second viscosity, and the second viscosity is greater than the first viscosity;   (d) melting the second component, transferring the melted second component to the spin beam, and setting a second temperature, wherein the second temperature is lower than the first temperature; and   (e) co-extruding the first component and the second component to form a composite fiber, wherein the first component is in an amount of 50 wt % to 95 wt %, based on the total weight of the composite fiber, the second component is in an amount of 5 wt % to 50 wt %, based on the total weight of the composite fiber, the cross section of the composite fiber is in a substantially circular shape and has a maximum diameter and a circumference, the first component of the composite fiber has a central portion and a plurality of extension portions extending from the central portion to the circumference, a maximum length of the central portion is less than three quarters of the maximum diameter, the second component of the composite fiber has a plurality of outer portions, each outer portion is in a fan shape and is disposed between two extension portions, and the extension portions and the outer portions are alternately distributed in the circumference.   
     
     
         5 . The method according to  claim 4 , wherein the maximum length of the central portion of the composite fiber is greater than one-eighth of the maximum diameter, each extension portion of the composite fiber has a first end and a second end, the first end is close to the central portion, the second end is close to the circumference, the width of the second end is greater than the width of the first end, and the extension portions of the composite fiber are in a fan shape or a water drop shape. 
     
     
         6 . A non-woven substrate, comprising:
 a plurality of first fibers, wherein each first fiber has a central portion and a plurality of extension portions extending outwards from the central portion, the outer edges of the extension portions form a discontinuous circumference on a cross section of the first fiber, the circumference is in a substantially circular shape and has a maximum diameter, a maximum length of the central portion is less than three quarters of the maximum diameter; and   a plurality of second fibers, wherein each second fiber is in a fan shape and has a size matching with a space between two extension portions.   
     
     
         7 . The non-woven substrate according to  claim 6 , wherein the material of the first fibers is a polyester polymer, polyamide polymer or polyolefin polymer, and the material of the second fibers is nylon or a polyolefin polymer. 
     
     
         8 . The non-woven substrate according to  claim 6 , wherein the first fibers are in an amount of 50 wt % to 95 wt %, based on the total weight of the non-woven substrate, the second fibers are in an amount of 5 wt % to 50 wt %, based on the total weight of the non-woven substrate, the maximum length of the central portion is greater than one eighth of the maximum diameter, and the extension portions are in a fan shape or a water drop shape. 
     
     
         9 . A method for manufacturing a non-woven substrate, comprising:
 (a) providing a first component, wherein the first component has a first viscosity;   (b) melting the first component, transferring the melted first component to a first spin beam, and setting a first temperature;   (c) providing a second component, wherein the second component has a second viscosity, and the second viscosity is greater than the first viscosity;   (d) melting the second component, transferring the melted second component to a second spin beam, and setting a second temperature, wherein the second temperature is lower than the first temperature;   (e) co-extruding the first component and the second component, to form a composite fiber, wherein the first component is in an amount of 50 wt % to 95 wt %, based on the total weight of the composite fiber, the second component is in an amount of 5 wt % to 50 wt %, based on the total weight of the composite fiber, the cross section of the composite fiber is in a substantially circular shape and has a maximum diameter and a circumference, the first component of the composite fiber has a central portion and a plurality of extension portions extending from the central portion to the circumference, a maximum length of the central portion is less than three quarters of the maximum diameter, the second component of the composite fiber has a plurality of outer portions, each outer portion is in a fan shape and is disposed between two extension portions, and the extension portions and the outer portions are alternately distributed in the circumference;   (f) forming a fiber web with a plurality of composite fibers; and   (g) separating the first component and the second component in the composite fibers, to form a non-woven substrate.   
     
     
         10 . The method according to  claim 9 , wherein the maximum length of the central portion of the composite fiber is greater than one eighth of the maximum diameter, and in Step (g), the first component and the second component are separated by punching the fiber web with a water jet.