Commingled Yarn Composition for High Dispersibility and Low Void Ratio
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing commingled yarn using continuous thermoplastic resin fibers and continuous reinforcing fibers face challenges in achieving high dispersibility and minimizing voids, leading to reduced mechanical strength and bundling issues due to varying amounts of surface treatment agents.
Innovation Solution
A commingled yarn is developed with a surface treatment agent content of 2.0% or more by weight, combined with a void ratio of 20% or less, using a blend of thermoplastic resin fibers and reinforcing fibers, and a method involving immersion and drying to enhance dispersibility and reduce voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
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 patent optimizes the content of surface treatment agent or sizing agent to be 2.0% by weight or more but not exceeding 10% by weight relative to the total amount of continuous thermoplastic resin fiber and continuous reinforcing fiber. This parameter optimization resolves the contradiction by finding the optimal concentration range that provides sufficient sizability while preventing fiber aggregation and maintaining good dispersing property.
2Stability of the object's composition
If the amount of surface treatment agent is reduced, then the dispersing property of the continuous reinforcing fiber is improved, but the fiber falls from commingled yarn and bundling becomes difficult
Solution Approach 1:
The patent establishes that the content of surface treatment agent or sizing agent should be 2.0% by weight or more relative to the total amount of fibers. This minimum threshold ensures sufficient bundling property and prevents fiber falling, while the upper limit of 10% by weight prevents excessive aggregation that would harm dispersing property. This parameter range resolves the contradiction between dispersing property and bundling property.
3Stability of the object's composition
If the commingled yarn is manufactured with insufficient surface treatment agent, then the dispersing property is improved, but voids increase and mechanical strength degrades
Solution Approach 1:
The patent specifies that the content of surface treatment agent or sizing agent should be 2.0% by weight or more but not exceeding 10% by weight. This optimized parameter range ensures adequate fiber bundling and reduces void formation in the commingled yarn, thereby improving mechanical strength while maintaining good dispersing property of the continuous reinforcing fiber.
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 results in a commingled yarn with high dispersibility and minimal voids, improving mechanical strength and bundling efficiency, leading to enhanced physical properties and textile performance.
Implementation Method 1
the commingled yarn 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
Implementation Method 2
A commingled yarn is developed with a surface treatment agent content of 2.0% or more by weight, combined with a void ratio of 20% or less, using a blend of thermoplastic resin fibers and reinforcing fibers, and a method involving immersion and drying to enhance dispersibility and reduce voids
Data Source
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.