Composite Yarn with Functionalized Particles for Fire Resistance
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Solution Overview
Problem
Existing composite yarns face issues with fire resistance, manufacturing complexity, and environmental toxicity, particularly when used in textiles for sun-blocking applications, failing to meet stringent fire performance criteria like Euroclass Bs2d0 or Bs3d0 and being difficult to produce cost-effectively with standard glass textile yarns.
Innovation Solution
A composite yarn design incorporating a continuous multifilament core yarn with a matrix containing functionalized particles of less than 40 μm median size, dispersed homogeneously to enhance fire resistance, and a process using standard glass textile yarns with reduced torsion, along with a sheath, to improve cohesion and meet environmental standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional composite yarns are made with high torsion core yarns and standard glass textile yarns, then manufacturing complexity is reduced, but fire resistance and mechanical integrity deteriorate
Solution Approach 1:
The patent changes the torsion parameter of the core yarn from conventional high torsion to low torsion (specifically 0.5 to 2 turns per meter), which fundamentally alters how the matrix material distributes and bonds with the filaments. This parameter change enables improved fire resistance and mechanical integrity while simplifying the manufacturing process, as the low torsion allows for more uniform matrix distribution without requiring complex manufacturing adjustments
Solution Approach 2:
The patent employs a composite structure consisting of a core yarn with multiple filaments and a matrix material that penetrates between the filaments. This composite design, where the matrix forms a cohesive binding phase among the filaments, simultaneously improves fire resistance and mechanical properties while maintaining manufacturing feasibility through the low torsion configuration
2Strength
If standard glass textile yarns with high torsion are used, then ease of manufacture is improved, but cohesion and mechanical integrity worsen
Solution Approach 1:
The patent reduces the torsion parameter of the core yarn to 0.5 to 2 turns per meter, which fundamentally changes the spatial arrangement of filaments and allows the matrix material to effectively penetrate and bond between them. This parameter modification enhances cohesion and mechanical integrity while maintaining ease of manufacture, as the low torsion configuration naturally facilitates uniform matrix distribution without requiring complex manufacturing procedures
3Reliability
If conventional coating techniques are used without functionalized particles, then manufacturing simplicity is maintained, but fire performance and environmental compliance deteriorate
Solution Approach 1:
The patent incorporates functionalized particles into the matrix material, creating a composite matrix that provides both fire resistance and environmental compliance. These functionalized particles are dispersed within the matrix and penetrate between the filaments during the coating process, enhancing fire performance while the overall manufacturing process remains relatively simple due to the low torsion core yarn configuration that facilitates uniform distribution
Data Source
AI summary
A composite yarn comprising a continuous multifilament core yarn incorporated in a matrix, is characterized 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 (dv50) 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.