Metal detectable fiber and articles formed from the same
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Solution Overview
Problem
Current polymeric composite fibers are not detectable by X-ray or magnetic means, particularly when filled with stainless steel particulate, which limits their use in industries requiring contamination control, such as food, medical, and pharmaceutical production.
Innovation Solution
Incorporating 400 series stainless steel powder with a particle size of D90 < 16 micron into monofilament or bi-component fibers during the spinning process to create fibers that are detectable by X-ray or magnetic means, allowing for the detection of lost articles in production streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric fibers are filled with metal particulate to enable detection, then detectability is improved, but processing difficulty increases
Solution Approach 1:
The patent changes the particle size parameter of the metal particulate to D90 < 16 micron, which is small enough to be easily incorporated during standard spinning processes while large enough to maintain detectability. This parameter optimization resolves the contradiction between detectability and processing ease.
Solution Approach 2:
The patent creates composite fibers by combining polymeric material with metal particulate (400 series stainless steel, aluminum, or zinc) in specific weight percentages (1-25%). This composite approach enables both detectability through metal content and processability through the polymer matrix, resolving the contradiction between these two requirements.
2Object-affected harmful factors
If stainless steel particulate is used to maintain food safety standards, then contamination control is improved, but detectability worsens
Solution Approach 1:
The patent specifies using 400 series stainless steel particulate with D90 < 16 micron, which maintains food safety compliance while providing sufficient magnetic and X-ray detectability. The particle size and material selection resolve the contradiction between contamination control and detectability.
Solution Approach 2:
The patent distributes metal particulate non-uniformly within the fiber structure, with varying concentrations (1-25 wt%) depending on the specific application requirements. This local quality approach allows optimization of both food safety compliance and detectability in different regions of the product.
3Reliability
If metal particulate loading is increased to improve detection, then detectability is improved, but fiber performance deteriorates
Solution Approach 1:
The patent optimizes the metal particulate loading to specific weight percentages (1-25%), balancing detectability requirements with fiber mechanical performance. This parameter control ensures sufficient metal content for detection while maintaining adequate fiber strength and processability.
Solution Approach 2:
The patent allows different metal particulate concentrations in different fiber regions and product applications, enabling optimization of detectability in high-risk areas while maintaining fiber performance in structural regions, thus resolving the contradiction between detection and performance.
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 fibers and articles retain the processing and performance properties of conventional thermoplastic fibers while being detectable with commercial metal detectors and X-ray equipment, reducing contamination risks in sensitive industries.
Implementation Method 1
A particulate is distributed in the polymer in an amount to make the fiber detectable by X-ray detection or magnetic detection
Implementation Method 2
A particulate is distributed in the polymer in an amount to make the fiber detectable by X-ray detection or magnetic detection
Data Source
AI summary
A fiber is provided with a polymer having a cross-section and a length. A particulate is distributed in the polymer in an amount to make the fiber detectable by X-ray detection or magnetic detection. The particulate is present in a core, a sheath, or both portions of polymer matrix. A process of detecting a fabric article is provided that includes the formation of a fiber in the form of a polymer having a cross-section and a length. A particulate is distributed in the polymer. A fiber is formed into a fabric. A fabric article is then manufactured from the fabric. The fabric article passes through an X-ray detector or a magnetic detector. A signal is collected from the X-ray detector or the magnetic detector indicative of the presence of the fabric article.