Composite Antibacterial Fiber via Surface-Modified Copper Powder
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Solution Overview
Problem
Conventional antibacterial fibers and post-treatment methods face issues such as high costs, poor mechanical properties, safety risks, limited antibacterial effectiveness, and environmental pollution, along with low washing durability and competitiveness in the textile market.
Innovation Solution
A method for preparing composite antibacterial and deodorizing fibers using surface-modified copper powders and functionalized resin powders, involving mixing copper powders with surface modifiers and organic compounds to create a conductive nanopowder and functional composite resin, which are then blended to form a masterbatch and spun into fibers with enhanced mechanical properties and deodorizing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper powder is added to achieve antibacterial effect, then antibacterial performance is improved, but cost increases and mechanical properties deteriorate
Solution Approach 1:
The patent uses a coupling agent as an intermediary substance to treat the copper powder surface before incorporating it into the polymer matrix. This coupling agent creates a transition layer that improves the interface bonding between copper powder and polymer, thereby maintaining mechanical properties while preserving antibacterial functionality. The coupling agent mediates the interaction between the metal particles and the organic polymer matrix, preventing stress concentration at the interface.
Solution Approach 2:
The patent creates a composite material system consisting of copper powder, coupling agent, and polymer matrix. This composite structure allows the combination of antibacterial properties from copper powder with the mechanical strength of the polymer, while the coupling agent ensures proper interfacial adhesion. The composite approach enables simultaneous achievement of functional and structural requirements.
2Reliability
If copper powder is used for antibacterial function, then antibacterial effectiveness is improved, but safety risks increase due to explosion hazards
Solution Approach 1:
The coupling agent serves as a safety intermediary by coating the copper powder surface and reducing its reactivity. This surface treatment layer prevents direct contact between copper powder and oxygen or other reactive substances that could trigger combustion, thereby eliminating explosion hazards while maintaining the antibacterial copper ions release functionality.
Solution Approach 2:
The patent converts the potentially harmful reactive surface of copper powder into a beneficial coated surface. The coupling agent coating that would otherwise be seen as adding complexity actually serves to suppress the harmful explosive properties of fine copper powder while preserving its antibacterial benefits through controlled ion release.
3Ease of manufacture
If conventional antibacterial post-treatment is applied, then cost is reduced, but washing durability decreases and environmental pollution increases
Solution Approach 1:
Instead of applying antibacterial agents as a post-treatment finish, the patent incorporates copper powder with coupling agent directly into the polymer matrix during the fiber manufacturing process. This preliminary action ensures that the antibacterial functionality is built-in from the start, creating permanent antibacterial properties that withstand washing and mechanical stress, eliminating the need for subsequent treatment applications.
Solution Approach 2:
The patent uses composite material technology to integrate antibacterial copper particles within the polymer structure during manufacturing. This approach creates a homogeneous distribution of antibacterial agents throughout the material, providing durable functionality that survives washing, unlike surface-coated post-treatment methods that peel or wash off over time.
4Ease of manufacture
If conventional antibacterial post-treatment is used, then cost is reduced, but environmental pollution increases
Solution Approach 1:
The patent performs antibacterial functionalization during the primary fiber manufacturing process rather than as a separate post-treatment step. This preliminary action eliminates the need for additional chemical treatment baths and wastewater generation associated with conventional post-treatment methods, while maintaining cost-effectiveness through process integration.
Solution Approach 2:
The patent extracts the antibacterial functionalization step from the separate post-treatment process and integrates it into the main manufacturing flow. This extraction eliminates the need for additional pollution-generating treatment stages, removing the harmful wastewater generation aspect while preserving the cost benefits of integrated processing.
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
The method provides fibers with permanent antibacterial functions, improved mechanical properties, reduced environmental pollution, and increased export value, while maintaining costs comparable to conventional post-treatment methods.
Implementation Method 1
surface modifying copper powder: mixing a surface modifier with said copper powder at a temperature from 20-90° C. and a stirring speed from 500-2000 r/min to form a conductive nanopowder
Implementation Method 2
functionalization of resin powder: mixing organic benzenesulfonates or organic sulfates and hydrazides or polyamines to form a first mixture, and then further mixing with a resin powder at certain molar ratio to form a functional composite resin powder
Data Source
AI summary
The present invention provides a method for preparing a masterbatch and fibers with composite antibacterial and deodorizing functions including surface modifying a copper powder; functionalizing resin powder; and preparing the composite antibacterial and deodorizing masterbatch. The present invention provides a new antibacterial compounding mechanism to prepare new antibacterial and deodorizing masterbatch and fibers which have permanent antibacterial function, and the mechanical properties thereof can reach the standard of general fibers; fully meets the requirements of various weaving; the cost thereof is comparable to that on antibacterial post-treatment; and the pollution is reduced. The present invention can increase the export volume and additional value of the textiles.