Method for manufacturing high tenacity fiber and high tenacity fiber manufactured thereby
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Solution Overview
Problem
Current methods for manufacturing high tenacity yarns using nylon or polyester fibers are limited by low tenacity and high production costs, while HMPE fibers are expensive and glass fibers are brittle and difficult to process.
Innovation Solution
A yarn coating technique is employed using a coating material with 3 to 35 parts by weight of a mineral reinforcing agent per 100 parts by weight of polyurethane-based coating liquid to enhance tenacity and processability, allowing for the production of high tenacity yarns comparable to HMPE at a lower cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If HMPE fiber is used to manufacture high-strength gloves, then tenacity is improved, but production cost increases
Solution Approach 1:
The patent applies composite materials by combining nylon or polyester fibers with a coating composition containing polyurethane and mineral reinforcing agents (such as silica, alumina, or titania). This composite structure provides tenacity comparable to HMPE fiber while using cheaper base materials, thereby reducing production cost while maintaining high strength requirements.
Solution Approach 2:
The patent changes the physical and chemical parameters of the yarn by applying a coating with specific composition ratios (polyurethane and mineral reinforcing agents in defined proportions). This parameter modification enhances the tenacity of nylon or polyester yarn to reach levels comparable to HMPE, allowing cost-effective substitution of expensive HMPE fiber.
2Ease of manufacture
If nylon or polyester fiber is used to reduce production cost, then production cost decreases, but tenacity deteriorates
Solution Approach 1:
The patent transforms low-tenacity nylon or polyester fiber into a composite material system by coating it with polyurethane and mineral reinforcing agents. The mineral particles (silica, alumina, or titania) embedded in the coating matrix provide reinforcement, increasing the overall tenacity to match HMPE levels while maintaining the cost advantage of using nylon or polyester as the base fiber.
Solution Approach 2:
The patent modifies the mechanical parameters of nylon or polyester yarn through surface coating with a composition designed to enhance strength. The coating process changes the structural and mechanical parameters of the yarn, transforming it from low-tenacity to high-tenacity material suitable for protective gear applications.
3Strength
If glass fiber is used to improve tenacity, then tenacity is improved, but processability deteriorates due to brittleness
Solution Approach 1:
The patent replaces brittle glass fiber with nylon or polyester fiber that, when coated, provides comparable tenacity but superior processability. The coated nylon or polyester yarn maintains flexibility and durability during knitting and processing operations, avoiding the brittleness and dust generation issues associated with glass fiber while achieving similar strength performance.
Solution Approach 2:
The patent changes the material parameters from glass fiber to coated nylon/polyester fiber, which offers a better balance between tenacity and processability. The coating composition is specifically designed to enhance strength while maintaining the flexibility and processability characteristics of synthetic fibers, eliminating the brittleness problem of glass fiber.
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 produces yarns with tenacity comparable to HMPE while being thinner, improving processability and reducing production costs, enabling the use of nylon or polyester fibers in high-strength applications like gloves with a dense and soft texture.
Implementation Method 1
the coating material contains 3 to 35 parts by weight of a reinforcing agent composed of a mineral material per 100 parts by weight of a coating liquid containing polyurethane
Implementation Method 2
coating a yarn made of at least one of nylon and polyester with a coating material to obtain a coated yarn
Data Source
AI summary
The present invention relates to a method of manufacturing a high tenacity yarn and a high tenacity yarn manufactured thereby. More particularly, the present invention relates to: a method of manufacturing a high tenacity yarn, the method including coating a yarn made of at least one of nylon and polyester to obtain a coated yarn, wherein the coating material contains 3 to 35 parts by weight of a reinforcing agent composed of a mineral material per 100 parts by weight of a coating liquid containing polyurethane; and a high tenacity yarn manufactured thereby. Therefore, it is possible to manufacture a yarn having high tenacity and improved processability by processing a nylon or polyester yarn having a relatively low tenacity as compared with a high modulus polyethylene (HMPE) yarn by use of a yarn coating technique, and further to reduce production cost.