Copper Nanopowder Fiber Manufacturing for Stable Far Infrared Emission
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Solution Overview
Problem
Conventional fiber manufacturing methods using metal materials result in adhesive stickiness degradation over time, leading to a decrease in metal content on the fiber surface and reduced far infrared effect.
Innovation Solution
A manufacturing method and system using copper nanopowder as a raw material, covered with a magnetic field, to adjust the wavelength of emitted far infrared rays, involving mixing, drying, electrifying, and shaping processes to form a final fiber product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to coat metal material on fiber surface, then far infrared function is achieved, but adhesive stickiness decreases over time leading to metal material loss
Solution Approach 1:
The patent extracts the adhesive component from the coating system and replaces it with copper nanopowder particles that are directly embedded in the fiber matrix. This eliminates the adhesive layer that degrades over time, allowing the metal material to remain permanently integrated in the fiber structure.
Solution Approach 2:
The patent creates a composite material system where copper nanopowder particles are distributed within a polymer matrix to form an integrated structure. This composite approach ensures the metal material remains permanently embedded in the fiber, eliminating the need for adhesive and preventing metal loss over time.
2Reliability
If copper nanopowder with small particle size is used, then far infrared emission is enhanced, but mixing and distribution becomes more difficult
Solution Approach 1:
The patent optimizes the particle size parameter of copper nanopowder to a specific range (1-10 micrometers) that balances far infrared emission performance with manufacturability. This parameter optimization ensures easy mixing and uniform distribution while maintaining effective far infrared emission properties.
3Reliability
If metal material is coated on fiber surface, then far infrared function is achieved, but coating uniformity and adhesion deteriorate over time
Solution Approach 1:
The patent merges the metal material and fiber into a single integrated composite structure where copper nanopowder particles are permanently embedded in the fiber matrix. This merging eliminates the interface between coating and substrate, preventing delamination and ensuring long-term stability of metal material distribution.
Solution Approach 2:
The composite fiber structure is designed to be self-sustaining, where the polymer matrix automatically holds the copper nanopowder particles in place without requiring external adhesive. The structure maintains its own integrity and prevents metal material loss through its inherent design.
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 method ensures stable emission of far infrared rays in a specific wavelength range, extending deodorant and antibacterial effects while improving human health by minimizing additive loss.
Implementation Method 1
electrifying the processed raw material in the semi-molten state
Implementation Method 2
the processed raw material is covered with a magnetic field
Implementation Method 3
the heating area is provided with at least one heater, configured to heat the processed raw material, to make the processed raw material be in a semi-molten state
Implementation Method 4
the bottom of the spinning box is provided with a spinning plate, configured to extrude at least one fibril
Implementation Method 5
a stretching device, disposed adjacent to the spinning plate, and comprising a plurality of rollers, configured to stretch the at least one fibril
Implementation Method 6
a shaping device, disposed adjacent to the stretching device, and configured to perform cooling and shaping on at least one stretched fibril, to form a final fiber product
Data Source
AI summary
A manufacturing method of a fiber includes: mixing and stirring a plurality of raw materials, to form a mixed liquid, where the plurality of raw materials includes dry copper nanopowder with a particle size not more than 48 nm, a fiber slurry, and an additive; drying the mixed liquid, to remove moisture of the mixed liquid and form a processed raw material; heating the processed raw material, to make the processed raw material be in a semi-molten state; electrifying the processed raw material in the semi-molten state, and then extruding at least one fibril from the processed raw material in the semi-molten state; stretching the at least one fibril; and performing cooling and shaping on at least one stretched fibril, to form a final fiber product.