Method for preparing curved fibers

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.