High Surface Area Fiber and Method of Construction Thereof

Abstract

A high surface area fiber and method of construction thereof is provided. The high surface area fiber includes an inner fiber extending along a longitudinal central axis. The inner fiber has a plurality of legs extending lengthwise in generally parallel relation with one another and with the central axis. Each of the legs extends radially away from the central axis to a first peak. First channels are formed between adjacent legs in generally parallel relation with one another and with the central axis. At least some of the legs have protrusions extending laterally outwardly therefrom. The protrusions extend lengthwise in generally parallel relation with one another and with the central axis.

What is claimed is: 
     
         1 . A high surface area fiber, comprising:
 an elongate inner fiber extending along a longitudinal central axis, said inner fiber having a plurality of elongate legs extending lengthwise in generally parallel relation with one another and with said central axis, each of said legs extending radially outwardly from said central axis to a first peak, said legs being spaced circumferentially from one another by first channels extending between adjacent legs, at least some of said legs having protrusions extending laterally outwardly therefrom, each of said protrusions extending to a second peak, said protrusions being spaced from one another by second channels extending between adjacent protrusions; and   an outer sheath at least partially filling said first and second channels.   
     
     
         2 . The high surface area fiber of  claim 1  wherein said protrusions extend lengthwise in generally parallel relation with one another and with said central axis. 
     
     
         3 . The high surface area fiber of  claim 1  wherein each leg has opposite first sides, each of said opposite first sides having a plurality of said protrusions extending outwardly therefrom. 
     
     
         4 . The high surface area fiber of  claim 3  wherein said opposite sides of each leg converge toward said first peak. 
     
     
         5 . The high surface area fiber of  claim 4  wherein each protrusion has opposite second sides converging toward said second peak. 
     
     
         6 . The high surface area fiber of  claim 1  wherein said inner fiber is formed from a first material extending coincident with said central axis said outer sheath is formed from a second material, said first and second materials being different. 
     
     
         7 . The high surface area fiber of  claim 6  wherein said second material is water soluble. 
     
     
         8 . A method of constructing a high surface area fiber, comprising:
 extruding an inner fiber from a first material, the inner fiber extending along a longitudinal central axis with a plurality of legs extending lengthwise along the inner fiber in generally parallel relation with one another and with the central axis, each of the legs extending radially outwardly from the central axis to a first peak with first channels being formed between adjacent legs, at least some of the legs having protrusions extending laterally outwardly therefrom, each of the protrusions extending to a second peak with second channels being formed between adjacent protrusions; and   extruding an outer sheath about the inner fiber, the outer sheath being formed from a second material that is different from the first material, wherein the outer sheath at least partially fills the first and second channels.   
     
     
         9 . The method of  claim 8  further including extruding each leg having opposite first sides, and extruding a plurality of the protrusions extending outwardly from each of the opposite first sides. 
     
     
         10 . The method of  claim 9  further including extruding the opposite sides of each leg converging toward the first peak. 
     
     
         11 . The method of  claim 10  further including extruding each protrusion having opposite second sides converging toward the second peak.