Composite Fiber Core-Shell Structure for Impact Protection
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Solution Overview
Problem
Conventional protection products made from single-component fibers, such as polypropylene, lack sufficient strength and cannot provide effective impact protection for sports-related injuries.
Innovation Solution
A composite fiber structure comprising a core and a shell with the shell's melting temperature lower than the core's, where the shell is made of polyethylene or polypropylene copolymers and the core of polypropylene copolymers or homopolymers, allowing for the creation of a composite board with enhanced impact strength and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional single-component fiber (e.g., polypropylene) is used to make protection products, then the manufacturing process is simple, but the impact strength is insufficient and cannot provide good protection
Solution Approach 1:
The patent applies composite materials by combining two different polymer components (polypropylene and polyethylene) into a single fiber structure with a core-shell configuration. The core provides structural strength while the shell provides impact absorption, creating a composite fiber that achieves superior impact strength compared to single-component fibers.
Solution Approach 2:
The fiber is segmented into distinct functional regions: a core component and a shell component. This segmentation allows each component to perform its specific function - the core maintains structural integrity while the shell absorbs impact energy - thereby resolving the contradiction between simplicity and strength.
2Ease of manufacture
If the shell melting temperature is lower than the core melting temperature, then the moldability is improved, but the manufacturing process requires precise temperature control
Solution Approach 1:
The patent utilizes parameter changes by exploiting the difference in melting temperatures between the shell (lower) and core (higher) components. During molding, the temperature is controlled to melt the shell first, allowing it to flow and conform to the mold cavity, while the core remains solid to maintain structural integrity. This differential melting behavior enables excellent moldability with manageable temperature control requirements.
Solution Approach 2:
The invention leverages phase transitions of the two polymer components at different temperatures. The shell undergoes phase transition (solid to liquid) at a lower temperature, enabling it to be molded easily, while the core remains in the solid phase until higher temperatures are applied. This staged phase transition simplifies the molding process and reduces the need for extremely precise temperature control.
3Strength
If the shell strength is higher than the core strength, then the impact protection is improved, but the structural integrity may be compromised
Solution Approach 1:
The patent applies local quality by assigning different strength characteristics to different parts of the fiber structure. The shell, which contacts the impact force first, is designed with higher strength to absorb and dissipate impact energy. The core, which provides the backbone structure, has appropriate strength for maintaining overall fiber integrity. This localized differentiation of material properties optimizes both impact protection and structural stability.
Solution Approach 2:
The composite fiber structure combines materials with different mechanical properties in a synergistic arrangement. The higher-strength shell material provides impact resistance while the core material maintains structural continuity. Together, they create a fiber that achieves both superior impact protection and adequate structural integrity, resolving the contradiction between these two requirements.
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 composite board exhibits improved impact strength, moldability, low ductility, light weight, and high heat resistance, offering superior protection compared to single-component fiber boards.
Implementation Method 1
A melting temperature of the shell is lower than a melting temperature of the core... the composite fiber is heated at the temperature between the melting temperature of the shell and the melting temperature of the core
Data Source
AI summary
Provided are a composite fiber, a composite board and a method for manufacturing the composite board. The composite fiber is composed of a core and a shell formed around the core, a melting temperature of the shell is lower than a melting temperature of the core, and the strength of the shell is higher than the strength of the core. The composite fiber can be manufactured into a composite board with high impact strength, high moldability, low ductility, light weight and high heat resistance, and thereby meeting protection requirements.