Shaped Fibers: Types and Technologies



Shaped fibers are chemical fibers produced by spinning through spinnerets with specific geometric shapes, resulting in special cross-sectional shapes and functions. Conventional chemical fibers with circular cross-sections have disadvantages such as low surface luster, a waxy feel, susceptibility to soiling and pilling, poor water absorbency, and low covering power. Therefore, modifying these fibers to obtain improved performance has long been a continuous goal. Modification of synthetic fibers mainly includes physical and chemical methods, with physical methods being more common than chemical ones. Changing the fiber cross-section is a simple way to obtain different fiber properties and belongs to physical modification. Among physical modification methods, it ranks first and is the most important means for producing shaped fibers.

Types, Functions, and Applications of Shaped Fibers

Because there are many ways to modify fiber cross-sections, a wide variety of shaped fibers have been developed. According to cross-sectional shape, they can generally be classified as triangular, polygonal, flat, hollow, and diamond-shaped. In recent years, with improvements in shaped fiber production technology, fibers with better performance but greater manufacturing difficulty have continuously entered the market, such as complex-shaped fibers, porous hollow fibers with hollowness greater than 50 percent, and fine and ultra-fine denier shaped fibers. Depending on cross-sectional differences, shaped fibers exhibit different functions.

Triangular cross-section fibers

Triangular-shaped fibers exhibit excellent optical effects. When light is incident, total internal reflection occurs along certain edges inside the fiber, weakening luster in those areas while enhancing luster on other edges.
When the angle of incidence changes, the reflecting edges change accordingly, producing a “sparkling” effect. These fibers are mainly used in fabrics requiring a shimmering appearance, such as silk-like fabrics, wool-like fabrics, corduroy, velveteen and other pile fabrics, yarns, and decorative textiles.

Polygonal or multilobal cross-section fibers

Different cross-sectional shapes result in different fabric styles. Polygonal fibers have soft luster and are suitable for silk-like and linen-like fabrics, offering a smooth, soft, lightweight, and crisp hand. Multilobal fibers provide excellent hand feel and good thermal insulation, and can reduce the tendency of circular fibers to pill. They are suitable for wool-like and pile fabrics, giving strong three-dimensionality and a full, bulky appearance.

Flat cross-section fibers

Flat fibers possess good bending stiffness and flexibility, a soft touch, and a dry, breathable, and moisture-permeable feel. Products made from these fibers can match natural silk and linen fabrics in both performance and style, and are mainly used for wool-like and linen-like fabrics.

Production Technologies of Shaped Fibers

Shaped Spinneret Method

This method uses specially designed and manufactured shaped spinnerets combined with specific spinning processes and is the most widely used approach for producing shaped fibers both domestically and internationally. By improving and optimizing the machining technology of spinneret guide holes and micro-orifices as well as spinning techniques, shaped fibers with virtually any cross-sectional geometry can be produced. The degree of fiber shape complexity can also be continuously enhanced through processing improvements. Common shaped fibers include flat, oval, triangular, and cross-shaped types, while complex shapes include multilobal, king-character-shaped, and hollow fibers. Newly developed shaped fibers include fine-denier shaped fibers, porous hollow fibers, and high-shape-factor trilobal fibers. Compared with other processing methods, the shaped spinneret method features a short production process and highly versatile cross-sectional variations. Because no chemical additives are introduced, there is no damage to the polymer melt. This method preserves the inherent properties of synthetic fibers while imparting the desirable aesthetic qualities of natural fibers such as cotton, wool, silk, and linen, making it a highly promising modification technique.

Expansion Adhesion Method

In this method, spinneret orifices are designed as closely spaced circular holes, annular holes, or rectangular holes. During extrusion, the spinning melt undergoes an expansion effect, also known as die swell, causing adjacent melt streams to adhere to each other. Under appropriate temperature and cooling conditions, hollow or kidney-shaped cross-section fibers are formed. Due to manufacturing constraints, the range of achievable cross-sectional variations with this method is relatively limited.

Conclusion

In conclusion, shaped fibers represent a key direction in the development of modern textile materials. Through cross-section engineering and advanced spinning technologies, these fibers overcome the limitations of conventional round fibers and deliver improved comfort, functionality, and visual appeal. Their diverse structures enable enhanced thermal performance, moisture management, elasticity, and durability, meeting the growing demand for high-performance textiles. In particular, wet spinning technology plays a vital role in producing certain high-value shaped and composite fibers with precise structural control. With continued development of wet spinning machines and related equipment, shaped fibers will gain broader applications in apparel, home textiles, and technical textile fields.

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