Chitosan Yarn Sizing for Low-Water Weaving of Thin Fibers
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Solution Overview
Problem
Thin yarns made from natural animal fibers, vegetable fibers, or synthetic fibers are difficult to weave due to breakage, and existing methods using water-soluble PVA reinforcement yarns result in high water consumption, environmental issues, color fastness problems, and dimensional instability.
Innovation Solution
A process involving crosslinking chitosan or its derivatives as a sizing agent to enhance fiber cohesion and mechanical resistance, using UV radiation for crosslinking, and partial removal during finishing to maintain softness and improve dyeing and printing affinity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water-soluble PVA reinforcement yarn is used to improve weavability of thin yarn, then yarn breakage is reduced, but water consumption increases and environmental issues arise
Solution Approach 1:
The invention extracts and eliminates the water-soluble PVA reinforcement yarn from the weaving process. Instead of using PVA, the patent applies a different sizing agent that does not require dissolution in large volumes of hot water, thereby removing the source of high water consumption and environmental pollution while maintaining yarn reinforcement during weaving
Solution Approach 2:
The invention changes the chemical and physical parameters of the sizing agent from water-soluble PVA to a non-water-soluble alternative. This parameter change allows the sizing agent to remain effective at lower temperatures and without requiring dissolution in large volumes of water, thus resolving the contradiction between weavability improvement and water consumption reduction
2Reliability
If high temperature (85°C-95°C) is used to dissolve PVA reinforcement yarn, then complete dissolution is achieved, but color fastness problems and felting occur
Solution Approach 1:
The invention changes the temperature parameter from high (85°C-95°C) to low (below 40°C). The new sizing agent is designed to be removable at low temperatures, thereby eliminating the harmful effects of high temperature on color fastness and dimensional stability while still achieving complete removal of the sizing agent
Solution Approach 2:
The invention uses a sizing agent that is intentionally designed to be temporary and easily removable. The sizing agent serves its purpose during weaving and then is completely removed at low temperatures through washing, leaving no harmful residues. This approach allows complete removal (analogous to complete dissolution) without the harmful side effects of high temperature
3Reliability
If water-soluble PVA yarn is used for reinforcement, then weavability is improved, but environmental sustainability deteriorates due to petroleum derivative disposal
Solution Approach 1:
The invention extracts and removes the harmful PVA component from the system. By eliminating the petroleum-based PVA reinforcement yarn and its associated dissolution process, the patent removes the source of environmental pollution and waste water treatment issues, while maintaining the essential function of yarn reinforcement during weaving
Solution Approach 2:
The invention changes the chemical composition parameter of the sizing agent from petroleum-based PVA to an environmentally friendly alternative. This parameter change enables the sizing agent to be biodegradable or easily removable without creating environmental pollution, thus resolving the contradiction between weavability improvement and environmental sustainability
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 process improves weavability, mechanical properties, and environmental sustainability by providing high-density knit designs with enhanced resistance to pilling and felting, while maintaining softness and brightness, and reducing water and chemical consumption.
Implementation Method 1
said step of sizing is followed by crosslinking of the chitosan of said reinforcement product applied to the fibers of said yarn after sizing, such that a crosslinked reinforcement polymer is obtained from said chitosan
Implementation Method 2
sizing said yarn with said sizing solution to apply said reinforcement product to the fibers of said yarn by at least partial impregnation and/or coating
Data Source
AI summary
A process for improving weavability of a yarn is described. The process has a step of application of a chitosan-containing reinforcement product and a later chitosan crosslinking step.