Light-Storage Wire Extrusion for Wash-Stable Luminous Fabrics
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Solution Overview
Problem
Existing methods for creating light-reflective fabrics are unstable, as fluorescent materials used in reflective strips or yarns tend to break or peel off after repeated washing, and are not securely attached to the fabric for a long period.
Innovation Solution
A wire drawing process involving thermoplastic polyurethane rubber particles and inorganic particles, which are mixed, dried, extruded, cooled, stretched, and rolled to form a light storage wire that can be woven into fabric, allowing the fabric to absorb and emit light in dark environments, while maintaining particle attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If fluorescent material is added to reflective strips or yarns to create light-reflective fabric, then visibility in dark environment is improved, but the fluorescent material breaks or peels off after repeated washing
Solution Approach 1:
The patent combines thermoplastic polyurethane rubber particles with inorganic particles (such as glass beads or reflective particles) to form a composite wire structure. This composite material approach ensures that the light-reflective properties are maintained while the thermoplastic binder provides strong adhesion that prevents particle separation during washing, thus resolving the contradiction between visibility enhancement and attachment stability.
2Illumination intensity
If fluorescent material is added after yarns are obtained and then woven into clothes, then light reflective fabric is created, but the fluorescent material is not stable and cannot be secured for a long period
Solution Approach 1:
The patent incorporates the inorganic particles and thermoplastic polyurethane rubber particles into the wire structure before the weaving process. This preliminary integration ensures that the light-reflective particles are securely embedded in the fabric structure from the beginning, rather than being added later as a separate step that would result in poor adhesion and short duration of effectiveness.
3Illumination intensity
If reflective strips with fluorescent material are attached to clothes, then visibility in dark is improved, but the strips are not securely attached and detach easily
Solution Approach 1:
The patent merges the light-reflective inorganic particles directly into the wire structure during the wire drawing process, combining the functions of the wire and the reflective elements into a single integrated component. This eliminates the need for separate reflective strips that would require additional attachment steps, and the thermoplastic polyurethane ensures strong bonding of particles within the wire structure.
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 resulting fabric emits light in dark environments without particle separation, ensuring long-term visibility and secure attachment to clothing or other surfaces.
Implementation Method 1
a first drying step: using a dryer to dry the plurality of the mixed thermoplastic polyurethane rubber particles and remove excess water, so as to melt the plurality of thermoplastic polyurethane rubber particles to be adhered with the plurality of inorganic particles
Implementation Method 2
melt the plurality of thermoplastic polyurethane rubber particles to be adhered with the plurality of inorganic particles
Implementation Method 3
a first cooling step: cooling the initial wire in a cooling tank for a first time cooling process to shape a surface of the initial wire
Implementation Method 4
a hot-temperature remodeling step: softening the initial wire in a thermoplastic tank after the initial wire passes through the shaping area
Data Source
AI summary
A wire drawing process of a light storage wire includes a feeding step, a mixing step, a first drying step, a hot melt extrusion step, a first cooling step, a shaping/organizing wire step, a hot-temperature remodeling step, a stretching step, a second cooling step, a strand winding/rolling step, and a second drying step.