Cross-linked Ethylene Polymer Fabric Moldability
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Solution Overview
Problem
Existing knit fabrics for garments often lack a balanced combination of desirable properties such as dimensional stability, heat-set properties, stretchability, chemical resistance, abrasion resistance, and moldability, and may be limited by production methods like pulley feeding systems rather than eyelet systems.
Innovation Solution
A knit fabric comprising elastic fibers made from a reaction product of ethylene polymer and a cross-linking agent, with a cross-linking percentage between 10 to 90 weight percent, characterized by specific ethylene/α-olefin interpolymer characteristics that enable moldability and improved processability, including characteristics like average block index, molecular weight distribution, melting point, density, and elastic recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cross-linked ethylene polymer fibers with gel content ≥30 wt.% are used, then moldability is improved, but fabric processability and production efficiency deteriorate
Solution Approach 1:
The patent changes the gel content parameter from the conventional ≥30 wt.% to a specific range of 10-20 wt.%, which maintains adequate moldability while significantly improving fabric processability and production efficiency. This parameter optimization resolves the contradiction by finding the optimal balance point where sufficient cross-linking provides moldability without excessive cross-linking that would hinder production.
Solution Approach 2:
Instead of using high levels of cross-linking (≥30 wt.% gel content), the patent applies partial cross-linking at optimized levels (10-20 wt.% gel content), which is sufficient to achieve the desired moldability for lingerie applications without the harmful effects of excessive cross-linking on fabric processing and production throughput.
2Shape
If high gel content cross-linked fibers are used, then moldability is improved, but fiber breakage and defects increase
Solution Approach 1:
The patent optimizes the gel content parameter to 10-20 wt.%, which provides sufficient cross-linking for moldability while avoiding the fiber embrittlement and increased breakage associated with higher gel contents (≥30 wt.%). This parameter optimization maintains fiber strength and reduces defects.
3Length of moving object
If conventional ethylene/α-olefin interpolymer is used, then fabric stretchability is achieved, but dimensional stability and heat-set properties deteriorate
Solution Approach 1:
The patent creates a composite fiber structure by cross-linking ethylene/α-olefin interpolymer with cross-linking agents, forming a composite material that combines the stretchability of the elastomeric polymer with the dimensional stability and heat-set properties provided by the cross-linked network structure.
Solution Approach 2:
The patent modifies the polymer structure by introducing cross-links at optimized gel content levels (10-20 wt.%), which changes the physical and chemical properties of the material to simultaneously achieve stretchability, dimensional stability, and heat-set capability.
4Ease of manufacture
If pulley feeding system is used for fabric production, then production is possible, but productivity and throughput are limited
Solution Approach 1:
The patent changes the fabric properties by optimizing cross-linking parameters (gel content 10-20 wt.%), which improves processability and enables the fabric to be produced on more efficient eyelet knitting machines instead of being limited to pulley feeding systems, thereby increasing throughput and productivity.
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 fabric achieves a balanced combination of desirable properties, including moldability, improved processability, and enhanced performance in applications like bras and swimsuits, with increased throughput and reduced defects like fiber breakage.
Implementation Method 1
the elastic fibers comprise the reaction product of at least one ethylene polymer and at least one cross-linking agent, said cross-linking agent being any means which cross-links one or more of the fibers
Implementation Method 2
the fabric is capable of being molded, i.e., become set into a shape conforming to a three-dimensional mold when subjected to heat without substantial distension of the structure of the fabric
Data Source
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AI summary
Knit fabric compositions have now been discovered that often have a balanced combination of desirable properties. Said fabric compositions comprise fibers of olefin block interpolymers or homogeneous branched ethylene polymers or a combination thereof. The fibers are characterized by an amount of crosslinking such that the fabric is capable of being molded.