Method for manufacturing a three-dimensional formed structure in polyamide texiles
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Solution Overview
Problem
Polyamide 66, widely used in the textile industry for its mechanical properties, faces challenges in interfacial adhesion due to its low surface energy and requires harsh solvents for surface treatments, which are toxic and inefficient for forming three-dimensional structures.
Innovation Solution
Treatment of textile fabrics with a CaCl2/H2O/EtOH mixture under specific concentration, exposure time, and temperature conditions allows for the formation of three-dimensional structures with a combination of soft and hard segments without additional joining steps, enhancing dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyamide 66 is treated with harsh solvents (formic acid, cresol, phenol) for surface treatment, then surface energy and interfacial adhesion are improved, but toxicity and environmental harm increase
Solution Approach 1:
The patent changes the chemical parameters of the treatment solution by using CaCl2/H2O/EtOH mixtures with specific concentrations (CaCl2 >6 mol%, H2O >65 mol%, EtOH <30 mol%) instead of traditional harsh solvents. This parameter change maintains effective surface treatment and dissolution capabilities while eliminating toxicity and environmental harm associated with formic acid, cresol, and phenol
Solution Approach 2:
The patent introduces CaCl2 as an intermediary substance that mediates between the polyamide 66 and the benign H2O/EtOH solvent system. The CaCl2 enables complexation with polyamide carbonyl groups, facilitating dissolution and surface modification without requiring toxic solvents, thus acting as a bridge that achieves the desired effect without harmful factors
2Manufacturing precision
If polyamide 66 is dissolved in traditional solvents, then surface modification is achieved, but additional joining steps are required for three-dimensional structure formation
Solution Approach 1:
The patent merges the surface modification function and the three-dimensional structure formation function into a single integrated process. By using CaCl2/H2O/EtOH solutions that enable both dissolution/swelling and direct molding, the method combines what were previously separate operations (surface treatment plus joining steps) into one unified manufacturing step, eliminating the need for additional joining operations
Solution Approach 2:
The CaCl2/H2O/EtOH treatment solution exhibits multi-functionality: it acts as a solvent for surface modification, a swelling agent for dimensional change, and a molding medium for three-dimensional structure formation. This universal solution replaces multiple specialized agents and processes, achieving surface modification and structure formation simultaneously without requiring additional joining steps
3Shape
If polyamide fabric is swollen in CaCl2/H2O/EtOH mixtures, then three-dimensional structure formation is enabled, but fabric stability may be compromised
Solution Approach 1:
The patent precisely controls the parameters of the CaCl2/H2O/EtOH mixture (CaCl2 >6 mol%, H2O >65 mol%, EtOH <30 mol%) and processing conditions (temperature, time) to achieve the desired balance. These parameter changes ensure sufficient swelling for three-dimensional structure formation while maintaining fabric stability by preventing excessive dissolution or degradation that would occur with different compositions
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 method results in stable three-dimensional textile articles with improved bending stiffness, achieving dimensional stability and specific structural properties without compromising the fabric's basis weight, overcoming the limitations of prior surface modification techniques.
Implementation Method 1
Complexation of polyamide suppresses the hydrogen bonding between the polymer chains and causes dissolution of the polyamide. The interaction of the carbonyl group of polyamide 66 and Lewis acids enables Lewis acid-base complexation and dissolution of polyamide 66 in solutions containing GaCl3, AlCl3, CaCl2, BF3, or BCl3.
Implementation Method 2
The effect of swelling of polyamide 6.6 in a mixture of CaCl2/H2O/EtOH is disclosed in EP 3 378 988 A1. The polyamide fibre is exposed to a mixture of CaCl2/H2O/EtOH, wherein the CaCl2 content is > 6 mol%, the EtOH content is < 30 mol%, and the H2O content is > 65 mol%.
Implementation Method 3
Surface treatments such as plasma treatment, grafting and surface roughening with solvents are used. Li et al. used CaCl2/EtOH to modify the surface roughness of Kevlar fibres.
Data Source
Figure 1a~1c
Figure 2
AI summary
Method for manufacturing a three-dimensional formed structure from a textile fabric, comprising the steps of (a) providing a textile fabric comprising polyamide; (b) contacting the textile fabric with a treatment solution wherein the treatment solution comprises a mixture of CaCl2, EtOH and H2O, wherein the CaCl2 content is > 6 mol%, the EtOH content is < 25 mol%, the molar ratio between CaCl2 : EtOH : H2O is between 1 : 0.6 - 2 : 3.4 - 7 and the H2O/EtOH molar ratio is > 2.5. for at least 1 second and at most 4 hours by immersion or for at least 1 s and at most 5 minutes by spraying; (c) squeezing of the treatment liquid from the fabrics to adjust the solvent content in the fabrics; (d) consolidating the textile fabric for 1 s to 60 minutes while the textile fabric is still containing the treatment solution by increasing the temperature of the textile fabric to a temperature of between 10 °C to 120 °C with the provision that the temperature is at least 100 °C below the melting point of the polyamide and by forming the textile fabric in the desired three-dimensional structure; (e) quenching the treatment solution while the formed textile fabric still contains treatment solution by adding water and/or by evaporating ethanol out from the fabric; (f) isolating the formed textile fabric followed by washing and drying.