Bi-component Filament Sheath-Core Adhesion
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Solution Overview
Problem
Bi-component continuous filaments used in textiles, particularly in floor coverings, suffer from delamination over time due to separation of polymer components, leading to reduced durability and resilience under wear and tear.
Innovation Solution
A bi-component continuous filament design featuring a sheath-core arrangement with a binding agent, such as a polyolefin modified by an acid anhydride, to enhance adhesion between the polymer components, along with the use of polymers like polyamide, polyester, or polyolefin, and functional additives for improved properties like fire retardancy and color-fastness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bi-component continuous filament is made with two different polymer components in a sheath-core arrangement, then the filament can be used for thermal bonding and creating diverse textile styles, but the polymer components tend to separate over time causing delamination
Solution Approach 1:
The patent introduces a binding agent as an intermediary substance between the sheath and core polymer components. This binding agent adheres the two polymer components to each other, preventing delamination while allowing the filament to maintain its bi-component structure for thermal bonding and textile applications.
Solution Approach 2:
The patent creates a composite structure by combining two different polymer components (sheath and core) with a binding agent. This composite approach allows the filament to exhibit properties of both polymers while the binding agent ensures structural integrity, enabling both versatility in applications and reliability in performance.
2Strength
If high levels of wear and tear are applied to bi-component continuous filaments, then the filaments can withstand heavy use, but the polymer components separate leading to delamination
Solution Approach 1:
The binding agent serves as a mediator that reinforces the bond between sheath and core components under stress. During wear and tear, the binding agent maintains adhesion between the polymer components, preventing delamination even when the filament is subjected to heavy use and mechanical stress.
Solution Approach 2:
The binding agent provides beforehand cushioning by pre-establishing a strong adhesive bond between the polymer components. This pre-bonding protects the filament structure from delamination during subsequent wear and tear, cushioning against the harmful effects of mechanical stress before they can cause separation.
3Reliability
If a binding agent is added to adhere polymer components, then delamination is reduced and durability is enhanced, but the device complexity increases
Solution Approach 1:
The binding agent is applied locally at the interface between the sheath and core polymer components, rather than throughout the entire filament structure. This localized application enhances durability at the critical adhesion point while minimizing the overall complexity and material addition to the filament system.
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 solution significantly increases the tenacity and elongation of the bi-component continuous filaments, reducing delamination and enhancing durability, resilience, and color retention, making them suitable for a wide range of textile applications including floor coverings.
Implementation Method 1
a binding agent adhering the first polymer component to the second polymer component along a length of the filament
Data Source
AI summary
The present disclosure generally relates to bi-component continuous filaments and articles made therefrom. In one embodiment, a bi-component continuous filament is disclosed, comprising a first polymer component forming a sheath; a second polymer component comprising a core that is surrounded by the sheath; and a binding agent adhering the first polymer component to the second polymer component along a length of the filament; wherein an elongation of the bi-component continuous filament is between 33.6±5.0−60.4±5.0 percent; and wherein a tenacity of the bi-component continuous filament is between 1.9±0.2−3.9±0.2 grams per denier (GPD). In some embodiments, the first polymer component comprises a polyamide, polyester, or polyolefin material, preferably a cationic polyamide or a cationic polyester, the second polymer component comprises polyethylene terephthalate (PET), and the binding agent comprises a polyolefin modified by maleic anhydride.