Binder Viscosity Control for Fiber Dust Reduction
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Solution Overview
Problem
Existing dry processes for forming fiber-based items using thermoplastic resins often result in fiber dust falling from the final products, causing dust issues in manufacturing equipment due to the presence of minute particles like fiber fragments.
Innovation Solution
A binder containing a polyester with structural units derived from polyethylene terephthalate, polyvalent carboxylic acids, and trimethylolpropane, along with an aggregation inhibitor, is used to bind fibers, exhibiting a viscosity coefficient higher than 3500 P at 150°C, which effectively reduces the likelihood of fiber fragments falling by binding them to the surface of the fiber-based items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermoplastic resin is used to bind fibers in a dry process, then the fibers can be bound together to form fiber-based items, but fiber dust and fragments fall from the product causing dust accumulation in equipment
Solution Approach 1:
The patent changes the physical and chemical parameters of the binder by specifying a polyester with particular structural units (from polyethylene terephthalate, polyvalent carboxylic acids, and polyhydric alcohols) and controlling its viscosity coefficient to be 3000-10000 P at 150°C. This parameter optimization ensures the binder has appropriate adhesion while forming a surface layer that traps fiber dust
Solution Approach 2:
The patent creates a composite binder system combining polyester with specific structural units and an aggregation inhibitor. This composite material approach allows the binder to simultaneously provide strong fiber binding and suppress fiber dust generation through the synergistic effects of the polyester matrix and aggregation inhibitor
2Object-generated harmful factors
If the binder viscosity is increased to reduce fiber dust, then fiber fragments are bound more effectively, but the binder may not spread properly among fibers during heating
Solution Approach 1:
The patent optimizes the viscosity coefficient parameter within a specific range (3000-10000 P at 150°C) to balance two opposing requirements: high enough viscosity to bind fiber fragments and reduce dust, but low enough to allow proper spreading and penetration among fibers during the heating process. This precise parameter control resolves the contradiction between dust reduction and manufacturability
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 binder effectively reduces the occurrence of fiber dust and fragments falling from the fiber-based items, maintaining product integrity and minimizing equipment dust accumulation while ensuring stable storage and mechanical strength of the final products.
Implementation Method 1
a binder for forming a fiber-based item and for binding fibers... the binder effectively reduces the occurrence of fiber dust and fragments falling from the fiber-based items, maintaining product integrity
Implementation Method 2
The binder exhibits a viscosity coefficient higher than 3500 P (poises) at 150°C in dynamic viscoelasticity measurement
Data Source
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AI summary
A binder that is used for forming fiber-based items and that binds fibers contains a polyester and an aggregation inhibitor. The polyester contains a structural unit derived from polyethylene terephthalate, a structural unit derived from at least one polyvalent carboxylic acid, and a structural unit derived from at least one polyhydric alcohol including trimethylolpropane. The binder exhibits a viscosity coefficient higher than 3500 P at 150°C in dynamic viscoelasticity measurement.