Carbon Fiber Sewing Thread Coating for Friction Reduction
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Solution Overview
Problem
Existing sewing threads face challenges in maintaining a constant property profile due to issues with static and dynamic resilience, internal and external friction, and contamination from abrasion, particularly when used in elastomers, thermoplastics, and thermosets.
Innovation Solution
A sewing thread made from staple fiber yarns, primarily using carbon fibers, which are coated or impregnated with materials to enhance mechanical, thermal, and electrical properties, and processed to improve processing efficiency and reduce friction, allowing for better integration with matrix materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sewing thread is made from carbon fiber materials, then mechanical strength and thermal stability are improved, but internal friction and processing difficulty increase
Solution Approach 1:
A coating material is applied to the carbon fiber staple fibers to serve as an intermediary substance. This coating reduces internal friction between fibers during processing while maintaining the high mechanical strength of the carbon fibers. The coating acts as a mediator that enables easier handling and processing of the carbon fiber sewing thread without compromising its strength properties.
2Temperature
If carbon fiber staple fibers are used in sewing thread, then thermal stability is improved, but external friction and contamination from abrasion increase
Solution Approach 1:
The coating material on the carbon fiber staple fibers serves as a protective intermediary layer that prevents direct contact between fibers during sewing operations. This reduces external friction and minimizes abrasion-related contamination, while the carbon fiber core maintains thermal stability. The coating acts as a barrier that protects the environment from carbon fiber dust and debris.
3Ease of manufacture
If coating materials are applied to carbon fiber staple fibers, then processing properties are improved, but manufacturing complexity increases
Solution Approach 1:
The coating material is applied to the carbon fiber staple fibers in advance during the manufacturing process, before the fibers are twisted into sewing thread. This preliminary coating action ensures that the fibers have optimal processing properties from the start, reducing friction and improving handling. By performing the coating operation early in the process, the need for additional processing steps is eliminated.
4Ease of operation
If staple fiber yarn structure is used, then elongation and flexibility are improved, but consistency of property profile becomes difficult to maintain
Solution Approach 1:
The manufacturing process controls key parameters such as fiber length distribution, coating thickness, and twist level to maintain consistency in the sewing thread's property profile. By carefully managing these parameters during production, the staple fiber yarn structure can provide flexibility and elongation while ensuring batch-to-batch consistency in strength, friction, and other critical properties.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2
AI summary
The present invention relates to a sewing thread (10) and to a method for producing a sewing thread (10) designed either as or in the manner of a staple fiber thread having or made of one or more carbon fiber materials (20'), or designed having or made of one or more fiber materials (20'), wherein a part or all of the fibers (20) of the fiber material(s) (20') are coated or impregnated, either partially or entirely, using one or more coating materials (30') and/or impregnation materials (40') as a coating (30) or impregnation (40), wherein said fiber material(s) are coated or impregnated individually, as a group (25) or bundle (25) of fibers (20), or as a whole,