Patent ID: 8617444

Claim:
A method of preparing curved fibers, using an apparatus comprising: i. at least two curved bars preferably having a curvature less than or equal to 90 degrees; ii. a spacing rod; iii. hanging means; iv. supporting means; and v. means for heating the apparatus, wherein the spacing rod being arranged in between the curved bars such that their concave surfaces face each other, but leave at least one opening between them; the supporting means fixes the curved bars to the spacing rod; and the supporting means surrounds and maintains the arrangement of the curved bars, the method comprising: i. selecting the spacing rod and curved bars, and arranging them such that they provide a desired curvature and gaps between the curved bars; ii. fixing the spacing rod to the curved bars with hanging means; iii. selecting a continuous fiber strand, the fiber having a composition with a workability-temperature range; iv. wrapping the fiber strand around the curved bars to form a fiber-wrapped assembly such that the entire strand is in direct contact with the curved-bar surfaces; v. securing the supporting means around the fiber-wrapped assembly; vi. heating the assembly such that the fiber composition is heated to a temperature within its workability-temperature range; vii. quenching the assembly such that it is restored to a temperature below a softening temperature of the fiber composition; viii. cutting the wrapped fiber along the openings between curved bars; and ix. disassembling the apparatus and collecting the resultant curved fibers.