Liquid Color Masterbatch Viscosity Control for Fiber Dispersion
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Solution Overview
Problem
The textile industry faces challenges in achieving good color rendering properties in colored fibers due to uneven dispersibility of color powders during the fabrication of color masterbatch for fibers, leading to the need for excessive colorants.
Innovation Solution
A liquid color masterbatch composition with a specific ratio of colorant, lubricant, and carrier, optimized for viscosity and particle size, is used to ensure uniform mixing with polyester, resulting in a colored fiber with improved color rendering properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If color powders are stirred and mixed with plastic particles using conventional methods, then the color masterbatch can be fabricated, but uneven dispersibility occurs leading to color spots and poor color rendering property
Solution Approach 1:
The patent changes the physical state of the colorant from solid powder to liquid form, and optimizes the viscosity parameter of the liquid color masterbatch composition to between 13000-18000 cP. This parameter change enables better flow and dispersion characteristics, allowing the colorant to distribute uniformly throughout the plastic matrix without forming color spots, thereby resolving the contradiction between manufacturing precision and compositional stability.
Solution Approach 2:
The patent introduces a lubricant as an intermediary substance that facilitates uniform dispersion of the colorant in the plastic matrix. The lubricant acts as a mediator between the colorant and plastic particles, preventing aggregation and ensuring homogeneous color distribution, which addresses the issue of uneven dispersibility while maintaining color rendering quality.
2Manufacturing precision
If more colorants are added to compensate for poor color rendering property, then color rendering may improve, but the composition becomes unbalanced and waste increases
Solution Approach 1:
By changing the colorant from powder to liquid form and optimizing the viscosity to 13000-18000 cP, the patent achieves superior dispersion efficiency. This allows for reduced colorant dosage while maintaining or improving color rendering property, as the liquid colorant distributes more uniformly throughout the plastic matrix compared to conventional powder-based systems.
Solution Approach 2:
The patent creates a standardized liquid color masterbatch composition formula that can be replicated and applied consistently across different production batches. This standardized composition ensures optimal color rendering with precise colorant dosage, eliminating the need to add excess colorant to compensate for poor dispersion in conventional methods.
3Ease of operation
If the viscosity of liquid color masterbatch is not optimized, then mixing may be easier, but dispersibility and color consistency deteriorate
Solution Approach 1:
The patent identifies and optimizes the viscosity parameter to a specific range of 13000-18000 cP, which represents the optimal balance between ease of mixing and dispersibility. Within this viscosity range, the liquid color masterbatch maintains sufficient flowability for easy mixing while ensuring adequate thickness for uniform distribution and consistent color rendering, resolving the contradiction between operational ease and manufacturing precision.
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 liquid color masterbatch composition provides excellent dispersibility and color consistency, eliminating the need for additional colorants and ensuring the colored fibers have a vivid, stable color with good fastness to washing, sweat, and light.
Implementation Method 1
a viscosity of the liquid color masterbatch composition is between 13000 cP and 18000 cP
Implementation Method 2
the carrier includes a nonionic surfactant, an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, or combinations thereof
Data Source
AI summary
A liquid color masterbatch composition for fabricating a colored fiber includes 30.0 to 44.4 parts by weight of a colorant, 14.0 to 44.4 parts by weight of a lubricant, and 11.2 to 56.0 parts by weight of a carrier, in which a viscosity of the liquid color masterbatch composition between 13000 cP and 18000 cP.