Polyester Airbag Fabric Desizing for Stronger Coating Adhesion
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Solution Overview
Problem
The separation of sizing agents from polyester yarns during the weaving process leads to decreased peel strength between the textile substrate and coating layer, increased stiffness of airbag fabrics, and potential peeling issues when the airbag is deployed, due to the poor adhesive strength of acryl-based sizing agents with polyester yarns.
Innovation Solution
Applying a polyester-based sizing agent to the yarn, removing it under alkaline conditions (pH 8-10) after weaving, and forming a coating layer on the substrate to enhance air-tightness and reduce stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an acryl-based sizing agent is used to improve weavability during the sizing process, then the weaving process can be facilitated, but the sizing agent separates from the polyester yarn during weaving, leading to decreased peel strength and increased stiffness
Solution Approach 1:
The patent changes the chemical composition parameters of the sizing agent from acryl-based to polyester-based to improve compatibility with polyester yarn. This parameter change prevents separation during weaving while maintaining weavability, thereby resolving the contradiction between ease of manufacture and reliability
Solution Approach 2:
The patent employs a temporary sizing agent (polyester-based) that is intentionally designed to be removed after serving its purpose during weaving. The sizing agent is applied temporarily to facilitate weaving, then completely removed through alkaline treatment to prevent any negative effects on peel strength and stiffness
2Ease of manufacture
If a sizing agent is applied to improve yarn bundling and weaving properties, then the weaving process is improved, but the sizing agent remains as an impurity after weaving, decreasing peel strength and increasing stiffness
Solution Approach 1:
The patent extracts the harmful sizing agent impurity from the polyester yarn after the weaving process. By applying alkaline treatment with controlled pH (8-10) and temperature (40-90°C), the sizing agent is completely removed from the yarn surface, eliminating the stiffness problem while preserving the benefits of improved weaving
Solution Approach 2:
The patent applies a polyester-based sizing agent preliminarily before weaving to improve weaving properties. This preliminary application ensures smooth weaving process, and the sizing agent is subsequently removed in a controlled manner to prevent harmful effects
3Strength
If the adhesive strength between sizing agent and polyester yarn is poor, then the sizing agent separates during weaving, but improving adhesive strength is difficult with acryl-based agents on polyester
Solution Approach 1:
The patent achieves homogeneity by matching the chemical composition of the sizing agent (polyester-based) with the yarn material (polyester). This compositional homogeneity ensures strong adhesive strength between the sizing agent and polyester yarn, preventing separation during weaving while maintaining ease of removal after the process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents sizing agent separation, improves peel strength between the textile substrate and coating layer, reduces airbag fabric stiffness, and ensures better foldability and storability, enhancing the safety and performance of airbags.
Implementation Method 1
removing the sizing agent from the textile substrate under an alkaline condition of pH 8 to 10
Data Source
AI summary
Disclosed is a method for manufacturing a polyester fabric for an airbag that can not only prevent or minimize the separation of a sizing agent, which is provided to a yarn through a sizing process, during a weaving process, but can also maximize a peel strength between a textile substrate and a coating layer to be subsequently formed thereon and lower the stiffness of an airbag fabric by effectively removing the sizing agent from the textile substrate after the weaving process is completed. The method of the present invention comprises: applying a polyester-based sizing agent to a polyester yarn; manufacturing a textile substrate with the sizing agent-applied polyester yarn; removing the sizing agent from the textile substrate under an alkaline condition of pH 8 to 10; and forming a coating layer on the sizing agent-removed textile substrate in order to enhance air-tightness.