Understanding the Basics of Low Melt Polyester Fiber and Its Industrial Application

Table Of Content

There have been many strides in chemical textile fiber technology. The innovations help manufacture products with a unique character. Some of the latest include conjugation, bi-component spinning, and thermal bonding.

Low melt fiber is an example of a bi-component spinning. The technology combines two polymers with different qualities. The result is a fiber with an array of inventive uses.

Each innovation has an end goal for application or consumer use. The development goal of low melt staple fiber is managing the melting point.

Continue reading for more on these properties.

What is Low Melt Polyester Staple Fiber?

Low melt staple fiber (LMF) is a product of spinning polyester and modified polyester. It has a lower melting point of between 110 and 180 degrees Celsius.

The range of melting points meets the many performance needs of consumers.

A low melting point also ensures excellent bonding with other fibers.

The Production Process

The manufacture of low melt fiber is like the other PSF. But, instead of one reactor for MEG and PTA, they use two reactors during polymerization. One to produce regular polymer and a second for low melt polymer (modified polymer). The addition of Isophthalic acid (PIA) to the second reactor helps achieve a low melt point. They then moderate this melting point by controlling the amount of PIA.

The two methods in the formation of low melt fiber are;

1.Sheath/core

2.Side by side

Production of low melt fiber involves spinning two polymers with different chemical properties. The two components are a pure polyester core and an outer sheath with a low melting point. The low melting point polymer makes it easy for the fiber to combine into one during processing. When the outer sheath melts it forms a uniform bond and gives it specific properties. For instance, the high resilience and structural integrity is essential for non-woven products. The combining of low melt and solid fiber helps to give strength to the polyester fibers.

Application Areas

Different end uses of polyester staple fiber need varying melt points. The low melt fiber offers these ranges of melting points. There are two main types of low-melt fiber; standard and crystalline. The manufacturer creates black and crystalline fiber by adding dye and chemical.

Standard fiber comes in either black or white. Our low melt fiber Specs range between thicknesses of 2D, 4D to 6D, and a length of 51mm.

Crystalline low melt does not liquefy until it reaches its melting point. It withstands high temperature without softening. Hence, it’s great for automotive underbodies like wheel lining and near engine compartments.

The black low melt PSF is also suitable for use in the automotive industry because of its color. These are in the lining of the trunk, under the hood, and car carpeting. The white option is ideal for general applications.

Combining low melt fiber with solid fiber creates a fiber that works well in batting and wadding. It is common to mix low-melt fiber with 3D and 7D fiber for this purpose. In this case, the low melt fiber acts as an adhesive for bonding the two.

The application of low melt fiber involves a broad spectrum of downstream industries;

1.Home furnishing; in bedding to make mattresses, wadding for quilting, upholstery, and padding

2.Automotive; in car interiors, trunks, hood liners, carpeting, door trims, and wheel guards.

3.Industrial non-woven purposes; in hygienic products such as face masks, diapers, sanitary pad. As well as insulation and soundproofing material.

Advantages of Low Melt Fiber Over Other PSF

1.Its resilience means it has a broad scope of application.

2.Easy to process due to its even melting and bonding ability.

3.It requires no chemical adhesive. The low melting point of the fiber makes it possible to use heat sealing for bonding.

4.It’s eco-friendly; low melt fiber acts like glue when mixing with other fibers. For this reason, it eliminates the use of toxic chemical adhesive.

5.The bonding strength of low melt fiber is powerful. Thus, it maintains form longer.

6.Excellent bonding properties make it easy to mix with other fibers.

7.Low melt fiber can have a range of melting points by controlling the sheath polymer. The unique low melting points give this fiber a competitive edge useful for various end uses.

The unique properties of low melt fiber position it as a specialized fiber. Its use as a binder fiber adds strength to regular PSF for applications that need tenacity. Such applications include wadding, interlining, soundproofing, and automotive. As a lighter option, low melt fiber is replacing toxic plastic in the automotive industry.

It is an essential component for thermal bonding when creating non-woven fabrics. Statistics show using thermal bonding produces more for less energy. It’s thus, the solution to the increasing energy cost and impact of chemical bonding.

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