Antimicrobial Polyester Fiber Yarn with Volcanic Ash
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Solution Overview
Problem
Chemical fibers like polyester lack environmental friendliness and functional properties, while natural fibers like cotton face issues with mechanical strength and durability, making it difficult to develop products that meet modern demands for functionality and sustainability.
Innovation Solution
A method is developed to incorporate nano-sized volcanic ash into polyester fibers through a process involving crushing, heating, milling, and mixing with polyester to create an antimicrobial yarn that maintains the properties of both materials, utilizing Jeju volcanic ash with inorganic materials like SiO2, Al2O3, and TiO2, which are environmentally friendly and exhibit antimicrobial, deodorizing, and far-infrared-emitting functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyester fiber is used to improve mechanical strength and durability, then strength and washing fastness are improved, but environmental friendliness and functional properties deteriorate
Solution Approach 1:
The patent creates a composite material by incorporating volcanic ash particles into polyester fiber through master batch preparation. The volcanic ash content ranges from 1-10 wt% of the total fiber weight, combining the mechanical strength of polyester with the environmental and functional benefits of volcanic ash, including antimicrobial activity, deodorization, and far-infrared emission properties
2Object-affected harmful factors
If cotton fiber is used to improve environmental friendliness and moisture absorption, then environmental friendliness and moisture absorption are improved, but mechanical strength and dimensional stability deteriorate
Solution Approach 1:
The patent develops a composite fiber system where volcanic ash (1-10 wt%) is integrated into polyester matrix, creating a material that achieves both natural fiber benefits (environmental friendliness, moisture absorption enhancement) and chemical fiber advantages (mechanical strength, dimensional stability). The volcanic ash particles act as functional fillers that improve moisture management while maintaining structural integrity
3Object-affected harmful factors
If volcanic ash is incorporated into polyester to add functional properties, then antimicrobial activity and environmental friendliness are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by preparing a volcanic ash master batch before fiber production. The master batch is prepared by mixing volcanic ash with polyester resin and processing it into pellets containing pre-distributed volcanic ash particles (1-10 wt%). This preliminary preparation simplifies the subsequent fiber spinning process, as the volcanic ash is already uniformly distributed in the polymer matrix before extrusion, avoiding the need for complex post-processing or specialized spinning equipment
Solution Approach 2:
The master batch serves as an intermediary material that facilitates the incorporation of volcanic ash into polyester fibers. Instead of directly adding volcanic ash to the fiber spinning process, the patent uses master batch pellets as a mediator, which already contain pre-mixed volcanic ash and polyester resin. This intermediary step simplifies the manufacturing process by enabling uniform distribution of volcanic ash through standard extrusion equipment without requiring complex modification of the spinning line
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 resulting antimicrobial polyester fiber yarn exhibits excellent mechanical strength, antimicrobial activity, deodorization, and far-infrared emission while being environmentally friendly, with improved moisture absorption and washing fastness, suitable for various applications including textiles and industrial materials.
Implementation Method 1
heating the crushed volcanic ash
Implementation Method 2
allowing the heated volcanic ash to collide under an air stream in an air classifier mill system
Implementation Method 3
subjecting the volcanic ash powder to nano-milling to obtain nano-sized volcanic ash particles
Implementation Method 4
mixing the prepared nano volcanic ash with polyester for fiber use at a weight ratio of 10:90-30:70, followed by melt extrusion to prepare a volcanic ash master batch
Data Source
AI summary
The present invention relates to a method for producing an antimicrobial polyester fiber yarn containing volcanic ash, the method comprising the steps of: crushing and heating volcanic ash, and allowing the heated volcanic ash to collide under an air stream in an air classifier mill system to obtain volcanic ash powder; subjecting the volcanic ash powder to nano-milling to obtain nano-sized volcanic ash particles; disintegrating the volcanic ash particles to prepare nano volcanic ash; mixing the prepared nano volcanic ash with polyester for fiber use at a weight ratio of 10:90-30:70, followed by melt extrusion, thereby preparing a highly dispersed volcanic ash master batch; and mixing the volcanic ash master batch with polyester for fiber use at a weight ratio of 4:96-8:92, followed by spinning to produce an antimicrobial polyester fiber yarn.