Research on manufacturing of three component composite fiber with complex cross-section pattern

In this work, a preparation method of three-component composite fibers with complex cross-sectional patterns is proposed, and the fibers with complex cross-sectional patterns are fabricated using melt spinning. Initially, inspired by the shape of a fishbone, a spinning pack with three-component melt channels is designed for spinning fibers with a fishbone cross-sectional pattern. Then, the numerical simulation of the melt flow in the channels of the spinning pack is performed using Polyflow software. The spinning pack structure is optimized by analyzing the flow velocity distribution and shear rate distribution of different components within the spinning pack channels. The results show that smaller velocity fluctuations contribute to the clarity of the cross-sectional pattern. Thereafter, the spinning experiments are carried out based on the optimized spinning pack. The effect of the flow ratio between the three components on the cross-sectional pattern is discussed, and the three-component composite fibers with a clear fishbone cross-sectional pattern is obtained. Finally, in order to further study the effectiveness of the complex cross-sectional pattern fiber preparation proposed in this paper, another spinning pack for fibers with an H-shaped cross-sectional pattern is designed according to the aforementioned method, and spinning experiments are carried out. The SEM images of the cross-sections of fibers with fishbone and H-shaped cross-sectional patterns are obtained, verifying the feasibility of the method proposed in this paper. Moreover, the fibers with complex cross-sectional patterns obtained by this method have a certain anti-counterfeiting effect and can also be blended with other yarns to obtain fabrics with anti-counterfeiting effects.