Evolution of interfacial formation and configuration control of bicomponent fiber during full spinning process

As a result of the limitation of bicomponent spinning in which it is difficult to obtain the interface evolution of the fiber forming process and guarantee performance stability, numerical simulation was carried out to investigate the effect of cooling, melt viscosity, and inlet flow rate on the interface throughout the process. The results showed that the position deviation of the interface only occurred inside the orifice and the interface distortion continued until after extrusion, with the maximum deformation occurring during extrusion swelling. Based on sufficient multifield data obtained from the simulation, it was demonstrated that the interfacial curvature was governed only by the viscosity difference between individual components, and the position of the interface was determined by the mechanical energy of the bicomponent melt. Moreover, the curvature and the position of the interface can be adjusted indirectly by changing the viscosity ratio, which can be regulated by the flow ratio, bringing guidance for the full process control of the bicomponent fiber preparation.