Articles including coated fibers and methods of making coated fibers and articles
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Solution Overview
Problem
Existing methods for coloring and coating fibers lack durability and adhesion to various resin materials, especially when used in flexible or dynamic applications such as footwear and sporting equipment, where the coatings tend to dissolve or disperse, losing their decorative and aesthetic value.
Innovation Solution
A method involving the application of a coating composition with uncrosslinked polymers and optional colorants, which are then crosslinked to form an elastomeric matrix that bonds well to fibers like polyesters, polyethers, and glass/carbon fibers, ensuring the coating remains intact even when exposed to different resin materials and flexible during use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating methods are used to color and coat fibers, then the coating process is simple, but the coating lacks durability and adhesion, especially in flexible or dynamic applications
Solution Approach 1:
The patent applies parameter changes by transforming the coating material from conventional paint to a reactive polymer composition that undergoes chemical crosslinking. The polymer composition includes functional groups that form covalent bonds with fiber surfaces, changing the chemical parameters of the coating system to achieve superior adhesion and durability while maintaining processability through controlled crosslinking reactions
Solution Approach 2:
The patent employs composite materials by creating a hybrid coating system that combines organic polymer matrices with crosslinking agents and optional inorganic fillers or colorants. This composite structure integrates multiple material functions: the polymer provides flexibility and adhesion, while the crosslinked network delivers durability and chemical resistance, resulting in a coating that outperforms conventional single-material systems
2Adaptability or versatility
If the coating is made flexible for dynamic applications, then the coating can accommodate movement, but the coating tends to dissolve or disperse, losing its integrity
Solution Approach 1:
The patent applies preliminary action by pre-functionalizing the polymer composition with crosslinking agents and adhesion promoters before application. The coating is formulated in advance with reactive groups that will form a three-dimensional crosslinked network upon curing, creating a pre-established molecular architecture that simultaneously provides flexibility through polymer chain mobility and integrity through crosslinked bond strength
Solution Approach 2:
The patent implements local quality by creating regions of different crosslinking density and polymer composition within the coating layer. The coating structure varies locally to provide optimal flexibility in areas requiring movement while maintaining structural integrity in load-bearing regions, achieving both adaptability and compositional stability through spatially differentiated material properties
3Strength
If the coating provides strong adhesion to fibers, then the coating bonds well, but the coating may become rigid and less suitable for flexible applications
Solution Approach 1:
The patent applies parameter changes by controlling the crosslinking density and molecular weight of the polymer chains to achieve an optimal balance between adhesion strength and flexibility. The coating composition parameters are adjusted to create a network structure where sufficient crosslinking provides strong bonding to fibers while maintaining enough polymer chain mobility to accommodate flexing and dynamic movements without brittleness
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 provides a durable, aesthetically pleasing, and flexible coating that maintains its color and adhesion to fibers, even when integrated into composite articles and subjected to dynamic stress, enhancing the appearance and performance of articles like footwear and sporting equipment.
Implementation Method 1
the uncrosslinked polymers are crosslinked to form the matrix of crosslinked polymers
Implementation Method 2
applying (e.g., spraying) the coating composition onto the surface of the one or more fiber(s) and then curing it on the one or more fiber(s)
Implementation Method 3
the matrix of crosslinked polymers formed by curing the coating composition entraps the colorant and bonds the matrix including the colorant to the surface of the one or more fiber(s)
Data Source
AI summary
The present disclosure is directed to articles that include one or more coated fiber(s) (i.e., fiber(s) with a cured coating disposed thereon), where the coating includes a matrix of crosslinked polymers and optionally a colorant (e.g., pigment particles or dye or both). The cured coating is a product of crosslinking a coating composition including uncrosslinked polymers (e.g., a dispersion of uncrosslinked polymers in a carrier, wherein the uncrosslinked polymers are crosslinked to form the matrix of crosslinked polymers). The present disclosure is also directed to articles including the coated fibers, methods of forming the coated fibers and articles, and methods of making articles including the coated fibers.