Conductive Sheath-Core Conjugate Fiber Antistatic Durability
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Solution Overview
Problem
Conventional electrically conductive fibers face issues such as degradation of antistatic performance over time, low acid resistance, and poor durability due to the use of high amounts of carbon black fine particles, which affect spinnability and strength, leading to interfacial peeling and breakage during use.
Innovation Solution
An electrically conductive sheath-core conjugate fiber is developed with a thermoplastic polymer-based electrically conductive layer containing a specified amount of carbon black fine particles and a protective polyester-based core, optimized through a special spinning method that maintains fiber integrity and enhances adhesion, resulting in improved antistatic performance and acid resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of electrically conductive carbon black fine particles is added to the thermoplastic polymer to achieve satisfactory electrically conducting performance, then the electrical conductivity is improved, but the spinnability and stretchability of the polymer deteriorate drastically
Solution Approach 1:
The fiber is divided into two distinct components: a core component made of fiber-forming thermoplastic polymer and a sheath component made of electrically conductive thermoplastic polymer containing carbon black fine particles. This segmentation allows each component to be optimized independently - the core provides mechanical properties and spinnability, while the sheath provides electrical conductivity.
Solution Approach 2:
The invention uses a composite structure combining two different thermoplastic polymers with distinct functions. The core component (fiber-forming polymer) and sheath component (electrically conductive polymer with carbon black) are spun together as a conjugate fiber, creating a material that exhibits both good spinnability and satisfactory electrical conductivity.
2Strength
If stretching is performed to improve fiber strength and carbon black particle structure, then the fiber strength is improved, but the electrically conductive layer may be broken or its structure damaged
Solution Approach 1:
The core component provides mechanical support and cushioning to the electrically conductive sheath layer during stretching and processing. This protective effect prevents the carbon black-containing layer from breaking or having its particle structure damaged, while still allowing the fiber to be stretched to desired specifications.
Solution Approach 2:
The composite structure of core and sheath allows the core to bear the mechanical stress during stretching, protecting the sheath's electrically conductive structure. The differential properties of the two materials enable simultaneous achievement of fiber strength and electrical conductivity integrity.
3Reliability
If the electrically conductive layer contains a large amount of carbon black fine particles to achieve conductivity, then the electrical conductivity is improved, but the adhesiveness to the other polymer deteriorates and interfacial peeling occurs readily
Solution Approach 1:
By separating the fiber into core and sheath components with distinct material compositions, the invention eliminates the interfacial adhesion problem that occurs when carbon black is mixed throughout a single polymer matrix. The segmentation allows the electrically conductive layer to maintain its conductivity function without compromising the adhesive bond between layers.
Solution Approach 2:
The conjugate fiber structure combines two thermoplastic polymers in a core-sheath configuration, where the interface between core and sheath provides sufficient adhesion to prevent peeling during fabric production and use, while the sheath maintains its electrically conductive properties.
4Reliability
If conventional electrically conductive fibers are used, then initial electrical conductivity is achieved, but the antistatic performance degrades over time and shows low acid resistance and poor durability
Solution Approach 1:
The conjugate fiber combines two thermoplastic polymers where the core component provides enhanced mechanical strength and chemical resistance (including acid resistance), while the sheath component maintains electrical conductivity. This composite structure improves overall durability and resistance to degradation over time compared to single-polymer electrically conductive fibers.
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 fiber maintains excellent antistatic performance and acid resistance over long-term use, preventing degradation and ensuring durability, making it suitable for applications like dust-proof clothing and working wears where conventional fibers fail.
Implementation Method 1
an electrically conductive layer made of a thermoplastic polymer (A) containing a specified amount of electrically conductive carbon black fine particles
Implementation Method 2
conjugate spinning the resultant with another fiber-forming thermoplastic polymer
Data Source
AI summary
In an electrically conductive sheath-core conjugate fiber including an electrically conductive layer made of a thermoplastic polymer (A) containing electrically conductive carbon black fine particles which constitutes a sheath component and a protective layer made of a fiber-forming thermoplastic polymer (B) which constitutes a core component, the ratio of the (A) to the total weight of the (A) and the (B) is 10 to 35% by weight, the L1/L0 ratio is 1.04 to 10.0 where L1 represents the length of a boundary between the core component and the sheath component in a cross section of the conjugate fiber and L0 represents the length of the circumference of a circle having an area equal to a cross sectional area of the core component, the fineness, the strength at break and the elongation at break are each adjusted within specified ranges, the shrinkage in hot water at 100° C. is within a specified range, and the fiber surface coverage of the sheath component is 85% or more. This results in provision of an electrically conductive sheath-core conjugate fiber that is excellent in antistatic performance, which is hardly degraded even after long-term wearing, that is maintained for a long time, and that is excellent in durability. A method for producing the electrically conductive sheath-core conjugate fiber and a dust-proof clothing using such a fiber are also provided.