BICOMPONENT FILAMENT YARNS

T
wo spinning concepts for the
economic production of high
quality bico filament yarns
New system concepts
promise tailor made solutions for all
applications.
Although bicomponent yarns have
for spinning
been around for about 50 years now and
they are not a new phenomenon, we have
seen a constant increase in demand over
bicomponent
the past few years (with frequent fashion-
related peaks in 2015, for example).
Reasons for this development are
filament yarns
manifold. In addition to current fashion
Günter Schütt and Susanne Beyer
trends, new, highly-efficient solutions for
Oerlikon Barmag, Zweigniederlassung der Oerlikon Textile GmbH & Co KG
manufacturing textile fabrics such as
Leverkuser Straße 65, D-42862 Remscheid, Germany www.oerlikon.com/manmade-fibers
circular knitting, for instance, reduce
production costs. bicomponent yarns are frequently cross-sections are predominantly used
Bicomponent yarns offer a huge processed as bonding fibres for as staple fibres or as continuous
range of possible cross-sections. In nonwovens, the focus when manufac- filament in spunbond products. Major
general, these yarns comprise two turing side-by-side bicomponent yarns is applications are described herein.
different polymers, which give them on the desired self-crimping effect. Bicomponent fibres or bicomponent
specific properties. Bicomponent yarns Segmented-pie and islands-in-the-sea filaments are frequently used as bonding

Fig 1 : Each cross-section provides specific properties for the bicomponent yarn

with the corresponding cross-sections cross-sections are mainly manufactured fibres or filaments to bond the actual
are manufactured depending on the for producing super-microfibers, i. e. fibers and filaments together. In the case of
desired application. Here, the four best- less than 0.3 dpf. carded nonwovens, for example, the
known cross-sections are core-sheath, sheath polymer of a bicomponent staple
side-by-side, segmented-pie and islands- Diverse cross-sections fibre is melted on in an oven. The melting
in-the-sea. ensure diverse yarn point of the sheath material is lower than
Core-sheath and side-by-side cross- that of the core material, with the result
properties
sections are typical and often used in that the core fibres adhere at the crossing
staple fibre yarns, while the other two The most wide-spread are core- points. Here, the sheath is usually
completely dissolved and consequently
acts as an adhesive. To ensure sufficient
With Oerlikon Manmade Fibers segment dual adhesion, the sheath ratio of the fibre is
temperature system, sensitive polymers are processed relatively high at around 50%.
Frequently used polymer combina-
into high-quality bicomponent fibres and filaments. tions (core/sheath) include PET/CoPET
(low melt) and PP/PE.
cross-sections are predominantly sheath cross-sections; their applica- In the case of fibres and filaments
filament yarns. While core-sheath tions are extremely diverse. Core-sheath with special properties, additives or color

Asian Textile Journal z July 2016 z 28

 BICOMPONENT FILAMENT YARNS

and/or titanium-dioxide (TiO 2) master- combinations (sea/island) are PET/ of the dyeing process. In the past, the
batches are fed into the sheath polymer CoPET and PA/CoPET. Following the material ratios were frequently 50/50.
to achieve special properties. These can, fibre or filament manufacturing process, However, the ratio of PA6 has, for cost
for example, be functional polymers for the sea polymer is dissolved in an reasons, been consistently reduced over
hydrophilization or antibacterial alkaline solution, so that only the time and now lies at 20%.
properties. PE is a popular choice as the island filaments are left. This process
Demanding technology for
sheath for fibres and filaments for hygiene creates micro filaments with titers as
products with the aim of improving their low as 0.03 dtex. Within the market, 37
demanding yarns
tactile properties. Here, the sheath ratio islands per filament is the established The stability of the bicomponent
lies between 10 and 30% and is therefore standard, although constructions with process is decisively influenced by the
as low as possible to keep the costs for up to 91 islands are possible at pressure differences in the spin pack: the
additives and masterbatches low. Oerlikon Neumag. However, the hole lower the pressure difference, the more
A very high proportion of the costs stable the process. Equally relevant is the
for manufacturing fibres and filaments quality of the polymer used. A stable
are attributed to the raw materials. One A very high proportion of the polymer of good, consistent quality and
option for lowering the costs is to costs for manufacturing fibres that is not particularly sensitive to
manufacture fibres and filaments with and filaments are attributed to temperature changes guarantees a stable
less expensive polymers in the core, the raw materials. spinning process. Low viscosity
such as B-grade polymer or recycled differences in the material and a narrow
material. The high-end and more molecular weight distribution are
expensive polymers form the sheath, density on the spinneret decreases in further requirements for a reliable
whose ratio is relatively low at between this case. Fibers and filaments with a bicomponent process.
10 and 30%. Typical material combi- sea ratio of 30% can be reliably Oerlikon Barmag and Oerlikon
nations here are RPET/PET, PP/PP and manufactured. Lower ratios are Neumag have been supplying systems
RPA6/PA6. possible; however, this increases the for the manufacture of bicomponent
risk of clotted island filaments. staple fibre yarns and filament yarns
The eccentricity of the core
Segmented-pie or orange-shaped since the mid-1980s and are hence
One special feature of the core-sheath cross-sections form the second group able to draw on extensive process
cross-section is fibres with eccentric of bicomponent microfibers/filaments. know-how and expertise. The two
cores. This results in a so-called self- These are found more in filament and manmade fiber systems constructors
crimp effect. Following spinning, the spunbond applications and less in staple have already equipped both staple fibre
filaments are drawn in a fibre line. The fibre applications. Filaments with 16 systems and systems used for the
eccentricity of the core and the resulting segments are most frequently used. manufacture of BCF, POY, FDY and
differing levels of stretch create the crimp However, filaments comprising 32 or 64 spunbond with bicomponent spinning
in the fibre or filament. segments can also be manufactured. machinery. Here, the primary focus
The same effect is achieved in the Mechanically splittable filaments are
case of side-by-side cross-sections. made from PET/PA6: these polymers have
With these, various polymers, such as a low adhesion among each other and
PP/PE, PET/PE, PET/CoPET are used, or the can be easily mechanically separated.
same polymers with differing viscosities In the case of nonwovens,
(PET/PET, PP/PP). Side-by-side fibres and separation is carried out
filaments are predominantly manu- using a water jet or, for
factured as circular or circular-hollow textile products,
cross-sections, although other cross- by means
sections are also possible. Typical textile
fabrics made from bicomponent yarns
with side-by-side cross-sections are
cord fabrics, for example.
Fine yarns: bicomponent
microfibers
Sea-island cross-sections form one
Fig 2 : Less senstitive
group of bicomponent microfibers/ polymers can be
filaments. They are manufactured as manufactured with the
staple fibers for imitation leather or as standard SP8xB bico
spinning unit
filaments for textile applications such
as velvet, for example. Typical polymer

Asian Textile Journal z July 2016 z 29

BICOMPONENT FILAMENT YARNS

was on the four cross-sections already temperatures. They are frequently beam as short as possible (Fig 3). Due to
mentioned. connected to an HTM circuit. the design of the dual-temperature
The requirements for the systems and However, systematic temperature system the dwell time of component B in
processes are becoming increasingly separation, as made possible in the the temperature ambit of component A
complex. Mixing ratios of 70/30 have case of the dual-temperature system, is is reduced significantly.
long been standard now, with larger nevertheless not always essential. For In the case of the dual-temperature
mixing ratios - such as 90/10 for core- some bicomponent processes - such system, the spinning pumps and melt
sheath bicomponent yarns - increasingly as processing recycled polymer or B-
shifting into the foreground. grade polymer in the core and virgin
Cor respondingly, separate special polymer in the sheath, for example - Systematic temperature
temperature controls for each polymer the same process temperatures are set. separation is important in the
type and an expanded process window For some staple fibre and spunbond case of processing polymers
are standard for Oerlikon Barmag and products, the temperature transfer is which tend to have a high risk
Oerlikon Neumag concepts. also as in the case of the single- of degradation.
temperature system, although the
System concepts
process temperatures are very different.
With all bicomponent system One example of these is the core- distribution systems for component B
concepts, the temperature transfer for sheath fibres PET/PE: the processing are located in a separate housing.
the differing polymers A and B can be set temperature for PET is around 295 °C This, in turn, is connected to its own
separately all the way through to the spin
beam; in other words, for the extruder, Fig 3 : The new SP8xB dual
the melt filter and the polymer lines temperatue spin beam concept
ensures the strict temperature
through to the spin beam. separation between polymer
Depending on the polymer type, it is type A and polymer type B
recommended that the temperatures be
separated even more systematically. With
these concepts, the temperatures are
separated until directly before the
polymers reach the spin packs;
specifically the melt inlet lines, the
spinning pumps and the majority of the
melt lines from the spinning pumps to the
spin packs.
Depending on the system concept, the a n d
temperature transfer for polymer B differs around 210
in length (Fig 2). Irrespective of this, the °C for PE. This is
two polymers meet in the spin pack. Here, possible because PE is
a joint temperature level is achieved, relatively insensitive to higher
which results in the corresponding temperatures and the dwell times are
polymer viscosities. To ensure even low due to the throughput. HTM circuit;
spinning quality, the ratios of the polymer the transition to the
Dual-temperature system
viscosities should not be too disparate. housing with the spin packs is
In the case of side-by-side processes, The principle of this concept is consistently heated. Standard market
substantial differences in viscosity result the separate polymer transfer, each constructions where this is not the
in spinning errors. So-called ‘dog legs’, for with its own temperature control case have the significant disadvantage
example, lead to the melt flow bending just system up to just before the spin pack. that the melt in the non-heated areas
below the spinneret. Systematic temperature separation is freezes and forms a plug in the event of
important in the case of processing a production stop. This blocks the
Single-temperature system
polymers which tend to have a high melt f low, which brings the entire
This system concept includes risk of degradation, such as PS, TPU, system to a standstill.
separate temperature transfer up to the and several modified polymers, such as
SP8xB: special spin beam for
polymer entering the spin beam. The CoPET, CoPA6, CoPP, etc.
starting situation: polymer A (i.e. PET) For example, the monomer formation
sensitive bicomponent
has a process temperature greater than of PA6 increases exponentially to the
filament yarns
or equal to polymer B (i.e. PA6). Generally, processing temperature. For sensitive Thanks to a new spinning system
the distribution lines for polymer A and polymers, it is necessary to keep the concept, sensitive polymers can now
the spin beam have the same dwell time within the higher tempered spin also be processed to make bicomponent

Asian Textile Journal z July 2016 z 30

 BICOMPONENT FILAMENT YARNS

yarns in the filament yarn segment. The The new system is based on the SP8x recommended for microfibers and
basis of the new technology is the spin beam concept and, needless to say, temperature-sensitive polymers.
above-described dual-temperature offers energy cost advantages compared However, most co-polymers available
system. to the rectangular concept, such as on the market are considerably more
With this, the quality and the viscosity considerably lower heating power. Less stable and hence more temperature-
of the polymers can be accurately adju- sensitive polymers can also be independent than even a few years ago.
sted in accordance with the respective effortlessly manufactured using the Correspondingly, the ratio of polymers
process requirements. The stringent standard SP8xB bicomponent spinning for which systematic separation of the
unit. The new spinning system concept temperature transfers right up to the spin
is available both for the single-row and – pack is essential now lies at between
Oerlikon Barmag and Oerlikon as a unique concept within the market - 5 and 10%. The vast majority of cross-
Neumag offer tailor-made for the two-row, Z-design arrangement sections can be manufactured using the
concepts for all applications. spin pack. single-temperature system. This in turn
has significant cost advantages in
Summary production.
separation of the HTM heating systems of With the patented Oerlikon Manmade
both polymer lines and the spinning pump Oerlikon Barmag and Oerlikon Fibers segment dual temperature system,
ensure the least possible damage to each Neumag offer tailor-made concepts for all sensitive polymers are processed into
polymer type right up to the point at which applications. For standard polymer and high-quality bicomponent fibres and
the two components are combined in the standard cross-sections, the single- filaments. This concept also offers yarn
spin pack, hence guaranteeing optimum temperature system is the ideal solution; producers a considerable degree of
spinning conditions. whereas the dual-temperature system is flexibility.

Oerlikon Barmag to present new baler yarn winder for

increased profitability at K 2016, Düsseldorf
At the K 2016 trade fair for plastics industry that will take geotextiles processes, but now also for baler yarn processes -
place from 19-26 October in Düsseldorf, Oerlikon Barmag compared to standard machines available on the market.
will be exhibiting its new EvoTape 800 and WinTape mini
developments in the fields of also aim to offer an economical
extrusion equipment and pump solution for sack and big bag fabric.
engineering. WinTape mini was developed
With its Oerlikon Barmag and specifically for the production of
Oerlikon Neumag brands, Oerli- tape yearns which are round-
kon Manmade Fibers segment is woven during further processing.
the market leader for manmade
High-speed extrusion
fibre filament spinning systems,
texturing machines, BCF
pump
systems, staple fibre systems In Hall 10, dedicated to pump
and artificial turf systems. As a engineering, Oerlikon Barmag's
service provider, it offers Combined with the automatic WinTape tape yarn winder the pump specialists will be presenting
engineering solutions for the EvoTap extruder is said to offer an increase in profitability of the new high-speed extrusion
as much as 50%.
entire textile value added chain. pump, which is said to achieve
greater throughput rates with a lower investment volume. With the
Tape yarns for different applications increased speeds it is possible to achieve a much greater
In Hall 16, where the company will discuss extrusion throughput setting range reducing pulsation at the same time, the
equipment, the main focus will be on solutions for tape production. company explains. Furthermore, the reduced friction surfaces are
The new developments from the Chemnitz-based think tank focus said to make for a smaller temperature increase in the melt and
mainly on the EvoTape machine combined with the automatic therefore for more efficient and energy-saving production.
tape yarn winder WinTape and - a trade fair premiere - an The improved process characteristics with higher throughput
automatic baler yarn winder. rates come on top of other benefits offered by the Oerlikon
Presented for the first time at the K three years ago, the com- Barmag extruder pumps. According to the manufacturer, these
bination of tape system and winder is said to offer significant profit- include a marked volumetric efficiency, a special compressive
ability increases of as much as 50% - not only for carpet backing and strength, high leak tightness and long service life.

Asian Textile Journal z July 2016 z 31