丝绸2025，Vol.62Issue(9)：70-82,13.DOI:10.3969/j.issn.1001-7003.2025.09.008
海岛型超细纤维成型技术及应用研究进展
Progress on processing and application of islands-in-the-sea microfibers
摘要
Abstract
The conventional spinning process faces challenges in stably producing microfibers below 1 dtex,often resulting in uneven stretching,filament breakage,and fuzzing.However,the breakthrough in islands-in-the-sea fiber spinning technology has effectively resolved these issues.Islands-in-the-sea microfibers have garnered significant research attention due to their large specific surface area and low bending stiffness,which enable the production of fabrics with exceptional softness,fine texture,excellent drape,thermal insulation,and filtration properties.These superior characteristics make them widely applicable across various fields.However,during the formation of islands-in-the-sea fibers,the polymer blending system is influenced by multiple factors including the characteristics of polymer raw materials and spinning processes,resulting in randomness in both the quantity and size of the island phases.Therefore,systematic investigation of the formation mechanism of islands-in-the-sea fibers and clarification of the structure-property relationship hold significant theoretical value and practical importance for controlling fiber morphology and promoting industrial applications. This paper provides a systematic review of islands-in-the-sea microfibers,encompassing their developmental status,advancements in production equipment(domestic and international),fabrication methods,and fibrillation processes,with particular emphasis on the influential factors during fiber spinning and formation.The study conducts in-depth analysis from two critical aspects:polymer material properties and spinning processes.In terms of polymer material properties,the molecular weight and its distribution significantly affect melt fluidity.An increase in molecular weight elevates melt viscosity,consequently raising spinning pressure,which may lead to spinneret clogging.A lower melt flow rate(MFR)in the continuous phase facilitates the formation of microfibers with smaller diameters.The viscosity ratio between polymer melts determines the sea-island phase distribution during blending.Specifically,the component with higher viscosity tends to form the island phase,while the lower-viscosity component preferentially constitutes the sea phase.A lower viscosity ratio facilitates the formation of dispersed-phase microfibers with both reduced diameter and enhanced size uniformity.The interfacial tension is intrinsically related to the intermolecular forces between the two polymer phases.A reduction in intermolecular forces leads to increased interfacial tension,which directly affects fiber diameter distribution-resulting in uneven drawing and increased fiber diameters.The blending ratio significantly influences the phase structure:the component with a lower proportion tends to form the island phase,while the higher-proportion component preferentially constitutes the sea phase.Notably,phase inversion may occur when the ratio becomes highly disproportionate.In terms of spinning processes,the spinning temperature regulates the melt viscosity ratio-lower temperatures increase melt viscosity,thereby raising pressure in spinning assemblies.Shear rate influences the morphology of the dispersed phase,with higher shear rates promoting fiber refinement.The draw ratio optimizes fiber fineness,uniformity,and mechanical properties;higher draw ratios can enhance crystallinity while reducing fiber diameter.This study elucidates for the first time the relationship between polymer characteristic parameters,spinning processes,and the morphological structure of island phases in islands-in-the-sea fibers. At present,islands-in-the-sea microfibers have been widely applied in artificial leather,filtration,and acoustic absorption materials due to their unique structure and superior performance.However,challenges persist in their spinning process,including limited polymer material options and complex process control requirements.Future research will focus on three major aspects:developing novel polymer materials through copolymerization,blending,or modification to expand compatible component systems,and ensure immiscibility and solubility differences between the two phases,so as to expand the range of compatibility-tunable material systems;advancing multifunctional development by incorporating techniques like graft copolymerization to endow fibers with flame retardancy,waterproofing,and smart-responsive properties;optimizing fibrillation processes,including eco-friendly water-soluble polymers and green solvent recovery technologies,to achieve sustainable production.Through these multidimensional improvements,islands-in-the-sea microfibers are expected to enable broader applications in high-end functional materials.关键词
海岛型超细纤维/复合纺丝/共混纺丝/岛相形态/开纤工艺/应用Key words
islands-in-the-sea microfibers/conjugate spinning/co-spinning/island phase morphology/fibrillation process/application分类
轻工纺织引用本文复制引用
兰怡娜,唐孝颜,钱晓明..海岛型超细纤维成型技术及应用研究进展[J].丝绸,2025,62(9):70-82,13.基金项目
济南市人才项目(鲁化J[2022]5) （鲁化J[2022]5）
天津市研究生科研创新项目(2022BKY142) （2022BKY142）
