Commingled Yarn Composition for Dispersibility and Void Reduction
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Solution Overview
Problem
The commingled yarns made with continuous thermoplastic resin fibers and continuous reinforcing fibers face issues with dispersibility and void formation when varying amounts of surface treatment agents are used, leading to reduced mechanical strength and bundling difficulties.
Innovation Solution
A commingled yarn is developed with a controlled amount of surface treatment agent, where the continuous thermoplastic resin fibers and reinforcing fibers are blended into a fiber bundle and further treated with the agent, achieving high dispersibility and minimizing voids, thereby enhancing mechanical properties and bundling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the amount of surface treatment agent or sizing agent is increased, then the sizability is improved, but the dispersing property of the continuous reinforcing fiber degrades
Solution Approach 1:
The invention optimizes the concentration parameter of the surface treatment agent to a specific range (0.01-5% by mass relative to continuous reinforcing fiber) to achieve the best balance between sizability and dispersing property. This parameter optimization resolves the contradiction by identifying the optimal dosage that provides sufficient surface treatment without excessive aggregation.
Solution Approach 2:
The surface treatment agent acts as an intermediary substance that mediates between the continuous reinforcing fiber and the thermoplastic resin fiber. It provides appropriate surface modification to enhance bundling (sizability) while maintaining fiber separation (dispersing property) through its specific chemical composition and controlled application amount.
2Stability of the object's composition
If the amount of surface treatment agent is reduced, then the dispersing property is improved, but fiber falling increases and bundling becomes difficult
Solution Approach 1:
The invention establishes a minimum threshold for the surface treatment agent amount (0.01-5% by mass) to ensure adequate bundling performance. Below this threshold, the sizability deteriorates significantly. The specified range ensures sufficient surface treatment to maintain fiber cohesion while avoiding excessive agent accumulation.
Solution Approach 2:
The invention applies a small but sufficient amount of surface treatment agent (0.01-5% by mass) rather than large amounts. This partial action is adequate to achieve proper bundling and sizability without the harmful effects of excessive agent application, such as fiber aggregation and reduced dispersing property.
3Reliability
If the amount of surface treatment agent is increased, then the bundling is improved, but voids increase and mechanical strength degrades
Solution Approach 1:
The invention optimizes the surface treatment agent concentration to a specific range (0.01-5% by mass) that provides adequate bundling while preventing void formation. Excessive agent amounts lead to poor fiber distribution and increased voids, which compromise mechanical strength. The optimized parameter range achieves the right balance.
Solution Approach 2:
The invention converts the potential harm of surface treatment agent (which can cause aggregation and voids when excessive) into a benefit by precisely controlling its amount. The controlled application ensures proper bundling and fiber distribution, transforming what could be a harmful excess into a beneficial, optimized treatment that enhances both bundling and mechanical strength.
Data Source
Figure 1~4
AI summary
Provided is a commingled yarn having a dispersing property and having a smaller amount of voids, a method for manufacturing the commingled yarn, and a weave fabric using the commingled yarn. The commingled yarn comprises a continuous thermoplastic resin fiber, a continuous reinforcing fiber, and a surface treatment agent and/or sizing agent, comprises the surface treatment agent and/or sizing agent in a content of 2.0% by weight or more, relative to a total amount of the continuous thermoplastic resin fiber and the continuous reinforcing fiber, and has a dispersibility of the continuous thermoplastic resin fiber and the continuous reinforcing fiber of 70% or larger.