Composite yarn, manufacturing process and textile surface comprising such a yarn
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Solution Overview
Problem
Current composite yarns used for sun-blocking textiles face challenges in achieving high fire performance, manufacturing complexity, and environmental concerns, particularly in meeting stringent fire performance criteria like Euroclass Bs2d0 or Bs3d0, while being cost-effective and non-toxic.
Innovation Solution
A composite yarn design featuring a continuous multifilament core yarn with a matrix containing functionalized particles of median size less than 40 μm, dispersed throughout the inter-filament spaces, which reduces yarn titer and thickness, and uses a lower content of fire-retardant fillers, allowing for improved cohesion and homogeneity, and a simpler manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual coating of filaments with flame-retardant coating is used, then fire performance is improved, but yarn stiffness increases and manipulability deteriorates
Solution Approach 1:
The patent applies local quality by concentrating flame-retardant fillers specifically in the inter-filament spaces rather than uniformly coating each filament. This localized approach provides fire protection where most needed (at filament contact points) while maintaining overall yarn flexibility and manipulability.
Solution Approach 2:
The patent changes the parameter of filler distribution from individual filament coating to inter-filament space concentration. It also controls filler particle size (median 2-20 μm) and uses functionalized particles to achieve proper dispersion, transforming the physical and chemical parameters to resolve the contradiction between fire performance and flexibility.
2Reliability
If high content of fire-retardant fillers is used, then fire performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent optimizes the filler content parameter to a specific range (1-10% by weight) rather than using high concentrations. It also controls particle size distribution (median 2-20 μm) to achieve effective fire protection with minimal filler content, simplifying manufacturing and reducing costs.
Solution Approach 2:
The patent uses composite materials by combining organic polymer matrix with inorganic flame-retardant fillers (such as aluminum hydroxide, magnesium hydroxide, or antimony oxide). This composite approach achieves fire resistance through the synergistic effect of materials rather than relying on high filler content alone.
3Ease of manufacture
If large filler particles are used, then manufacturing is simpler, but dispersion homogeneity and filler distribution deteriorate
Solution Approach 1:
The patent precisely controls the particle size parameter of fillers, specifying a median size of 2-20 μm. This size optimization enables both easy handling during manufacturing and homogeneous dispersion in the polymer matrix, resolving the contradiction between manufacturing simplicity and dispersion quality.
Solution Approach 2:
The functionalized filler particles create a porous or network structure within the polymer matrix that facilitates uniform distribution. The small particle size allows them to penetrate and distribute evenly throughout the inter-filament spaces, achieving homogeneous dispersion while maintaining manufacturing simplicity.
4Reliability
If conventional flame-retardant fillers are used, then fire resistance is improved, but environmental harm increases due to toxic materials
Solution Approach 1:
The patent converts potentially harmful conventional fillers into beneficial eco-friendly alternatives. It replaces toxic halogenated fillers with non-toxic metal hydroxides (aluminum hydroxide, magnesium hydroxide) that provide fire resistance through endothermic decomposition, transforming the fire protection mechanism from toxic gas release to heat absorption and water vapor generation.
Solution Approach 2:
The patent changes the chemical composition parameters of the fillers from toxic halogenated compounds to non-toxic metal hydroxides. It also controls the particle size and surface functionalization to ensure proper dispersion and effectiveness, achieving fire resistance without environmental harm.
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 composite yarns with enhanced fire performance, reduced production costs, and compliance with environmental standards, enabling the production of textiles that meet stringent fire performance criteria while minimizing the use of toxic materials and volatile organic compounds.
Implementation Method 1
functionalized particles of median size less than 40 μm, dispersed throughout the inter-filament spaces
Implementation Method 2
comprising the heating of the polymer from the solid form to the liquid form in an extruder followed by deposition on the core yarn
Implementation Method 3
This dispersion is heated, which means that the plasticizer, starting at a certain temperature, becomes a solvent of the polymer. There is thus a change from a two-phase medium to a one-phase medium. This transformation, which is a sort of gelation, is irreversible.
Data Source
AI summary
A composite yarn comprising a continuous multifilament core yarn incorporated in a matrix is characterised in that the matrix comprises at least one polymer material and at least one reinforcing filler, the reinforcing filler being formed from functionalized particles, said particles having a median size (dv5o) of less than 40 μm. A process for manufacturing such a composite yarn, comprises at least one step of depositing, by coating or extrusion, a matrix comprising a polymer and a reinforcing filler, onto a core yarn. A textile surface comprises at least one such composite yarn.