1. What is Bico Yarn?
Bi-component yarns are continuous filaments made by extruding two different materials from the same spinneret using bi-component technology. These yarns have advantages over single-component yarns because they can be tailored for specific functions. Fiber attributes include anti-static, antimicrobial, super hydrophilic, super hydrophobic, stain resistance, low melt, and heat resistance. These yarns can be partially oriented (POY), fully oriented (FOY), or self-texturing.
Bicomponent yarn is often used to improve the functionality and performance of fabrics.
1.1 Structure Types
- Layered Structure: One fiber on the outer layer, another on the inner layer.
- Mixed Structure: Both fibers mixed throughout the yarn.
1.2 Performance Features
- Enhanced Functionality: Antibacterial, UV resistance, moisture-wicking.
- Improved Feel and Appearance: Soft, smooth feel, unique visual effects.
- Increased Strength and Durability: Combines fiber advantages for better durability and strength.
1.3 Applications
- Clothing: Sportswear, underwear, jackets.
- Home Textiles: Bed linens, curtains.
- Industrial Uses: Fabrics with special functions for industrial purposes.
1.4 Main Materials of Bico Yarn
- Polyester (PET): Strength, durability, heat resistance.
- Polypropylene (PP): Low density, good chemical resistance.
- Polyethylene (PE): Flexibility, abrasion resistance.
- Nylon (Polyamide, PA): High strength, excellent abrasion resistance.
- Co-Polyester (Co-PET): Adjustable properties, lower melting point.
- Polylactic Acid (PLA): Biodegradable, eco-friendly.
1.5 Common Combinations
- PET/PP: High strength, low weight, for nonwoven fabrics and filters.
- PET/PE: Soft feel, good abrasion resistance, for clothing and home textiles.
- PET/PA: Combines strength and elasticity, for sportswear and industrial fabrics.
- PP/PE: Lightweight and soft products.
2. Fiber Structures in Bicomponent Yarn
The fiber structures of Bico yarn come in various types, each with unique properties and applications:
2.1 Sheath-Core Structure
- Sheath: Outer layer with a lower melting point or special properties.
- Core: Inner layer with high strength and durability.
- Applications: Products needing special outer properties and inner strength.
2.2 Side-by-Side Structure
- Side-by-Side: Two fibers arranged side by side.
- Performance: Crimping and good hand feel, improving elasticity and softness.
- Applications: Elastic fabrics, clothing, textiles.
2.3 Segmented Pie Structure
- Structure: Fiber materials in a pie-segment shape.
- Performance: Enhances moisture absorption and dyeing.
- Applications: High moisture absorption and dyeing fabrics.
2.4 Islands-in-the-Sea Structure
- Structure: Polymer “sea” with embedded “island” polymers.
- Performance: After removing the “sea,” ultra-fine fibers remain.
- Applications: Ultra-fine fiber nonwovens and specialty textiles.
2.5 Matrix-Fibril Structure
- Structure: One material as the matrix, another as fibers within.
- Performance: High strength and good flexibility.
- Applications: High-performance composites and engineering fabrics.
3. Production Process of Bicomponent Yarn
The production process of Bico yarn involves several steps, from preparing raw materials to the final product. Here is a typical production process:
3.1 Raw Material Preparation
- Polymer Selection: Choose two polymers like PET and PE.
- Material Treatment: Ensure polymers are dry and impurity-free.
3.2 Extrusion
- Twin-Screw Extruder: Heat and melt the polymers separately.
- Melt Filtration: Filter melted polymers to remove impurities.
3.3 Spinning
- Spinneret Design: Create desired structures like sheath-core or side-by-side.
- Spinning: Extrude melted polymers into continuous filaments.
3.4 Cooling and Solidifying
- Air Cooling: Solidify filaments with cool air.
- Water Cooling (Optional): Some polymers may need water bath cooling.
3.5 Drawing
- Drawing Device: Stretch filaments to increase orientation and strength.
3.6 Winding
- Yarn Winding: Wind filaments into yarn packages.
3.7 Post-Processing
- Heat Setting (Optional): Enhance dimensional stability.
- Surface Treatment (Optional): Apply treatments like antistatic or antibacterial.
3.8 Quality Control
- Online Monitoring: Monitor fiber diameter and tensile strength during production.
- Laboratory Testing: Test samples to ensure they meet specifications.
3.9 Packaging and Storage
- Packaging: Pack yarn to prevent damage and contamination.
- Storage: Store in a dry, cool environment for shipping or further processing.
This production process ensures Bico yarn meets performance and quality needs. Adjusting parameters and equipment during production allows for specific properties to meet diverse demands.
4. Real-World Applications of Bicomponent Yarn
Bico yarn’s unique properties and structures make it valuable in many fields. Here are some real-world examples showcasing its effectiveness in different areas:
4.1 Sportswear
Example:
Brand: Adidas
Product: Climalite series sports shirts
Features: Uses PET/PP bicomponent yarn, combining PET’s strength and PP’s lightness. These shirts offer excellent sweat-wicking and comfortable wear.
Performance:
- Functionality: Great moisture-wicking, keeps the body dry.
- Comfort: Soft feel, suitable for intense workouts.
4.2 High-Performance Home Textiles
Example:
Brand: IKEA
Product: TEMPRANILLO bedding series
Features: Uses PET/PE bicomponent yarn, combining PET’s durability and PE’s softness. These bedding products are very comfortable and durable.
Performance:
- Durability: Long-lasting, not easily damaged.
- Feel: Soft and comfortable, enhances sleep quality.
4.3 Industrial Uses
Example:
Company: DuPont
Product: Kevlar reinforced fabric
Features: Uses PET/PA bicomponent yarn, combining PET’s strength and PA’s abrasion resistance. This fabric is used for bulletproof vests and safety gear.
Performance:
- Strength: High tensile strength, resists impact effectively.
- Abrasion Resistance: High durability, suitable for extreme environments.
4.4 Eco-Friendly Textiles
Example:
Brand: Patagonia
Product: Recycled Polyester Outerwear series
Features: Uses PLA/PET bicomponent yarn, with PLA providing biodegradability and PET adding strength and durability. These jackets excel in both environmental impact and performance.
Performance:
- Eco-Friendliness: Biodegradable materials reduce environmental impact.
- Durability: Excellent durability and functionality.
4.5 Elastic Fabrics
Example:
Brand: Lululemon
Product: Align Pants
Features: Uses PET/PE bicomponent yarn, providing soft elasticity and comfort. These yoga pants are designed for flexible movement.
Performance:
- Elasticity: Excellent stretch and recovery, ideal for various activities.
- Comfort: Lightweight and breathable, enhancing comfort during exercise.
4.6 Special Purpose Textiles
Example:
Company: 3M
Product: Fire-resistant insulation materials
Features: Uses PET/PP bico yarn, offering high-temperature resistance and good insulation. Widely used in building and industrial safety.
Performance:
- Heat Resistance: Excellent insulation properties.
- Safety: Protects workers from high-temperature hazards.
These examples show bicomponent yarn’s broad applications and excellent performance. With the right fiber combinations and structures, bicomponent yarn meets diverse product needs. It enhances functionality, comfort, and durability.
5. The Use of Low Melting Polyester Chips in Bico Yarn
5.1 Applications
- Nonwoven Fabrics
Thermally Bonded Nonwovens: These chips melt at lower temperatures to bond high melting point fibers, creating strong fabrics for medical, hygiene, and filtration uses.
- Spunbond and Meltblown Materials
Filtration Materials: Provide good bonding and filtration, ideal for high-efficiency filters.
Sound-Absorbing Materials: Used in panels and insulation due to their bonding properties.
- Clothing and Textiles
Composite Fabrics: Combine with high melting point fibers for soft, strong fabrics.
Lining and Filling Materials: Used in linings, bedding, and products needing softness.
- Building and Automotive Industries
Insulation and Soundproofing: Offer stability and bonding for insulation and soundproofing.
Composite Material Reinforcement: Enhance structural strength in composites.
5.2 Advantages
- Low-Temperature Bonding: Melt and bond at lower temperatures, saving energy and preventing damage.
- Enhanced Stability: Improve fiber stability and mechanical properties.
- Improved Feel and Softness: Create smooth, soft fabrics.
- Versatility: Achieve functions like waterproofing and antistatic properties.
- Environmental Friendliness: Some are recyclable, reducing pollution.
6. The Use of Cationic Polyester Chips in Bico Yarn
6.1 Applications
- Clothing Fabrics
High Moisture Absorption: Improve comfort for sportswear and underwear.
High-Performance Dyeing: Produce vibrant colors for fashion and home textiles.
- Nonwoven Fabrics
Medical and Hygiene Products: Provide antibacterial and quick-drying properties for medical and sanitary products.
Filtration Materials: Excellent adsorption and stability for high-efficiency filters.
- Home Textiles
Bedding: Create comfortable, colorfast sheets and pillowcases.
Curtains and Decorative Fabrics: Offer light resistance and vibrant colors.
- Functional Textiles
Antistatic and Antibacterial: Ideal for workwear and bed sheets.
Eco-Friendly Textiles: Can be combined with eco-friendly materials for sustainable products.
6.2 Advantages
- Excellent Dyeing Performance: Dye vividly and firmly at low temperatures.
- Enhanced Functionality: Good moisture absorption, antistatic, and antibacterial properties.
- Improved Comfort: Soft and smooth for a better feel.
- Eco-Friendliness: Can be combined with recycled polyester for sustainable textiles.
- Multifunctional Composite Materials: Can include features like UV resistance and waterproofing.
