Method for producing coated polyolefin fibers, and a fibrous composite
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Solution Overview
Problem
Existing methods for preparing ultra-high molecular weight polyethylene (UHMW PE) yarns face challenges with fiber surface finishes interfering with polymeric binder adhesion, leading to reduced bond strength and ballistic resistance, and surface treatments have a limited shelf life, requiring immediate composite fabrication.
Innovation Solution
A process involving the removal of fiber surface finishes, followed by plasma or corona treatment to enhance surface energy, and application of a protective poly(alkyl-oxide) polymer coating to preserve the treated fibers, allowing for storage and later use in composite fabrication without fiber clumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fiber surface finish is applied to reduce static build-up and facilitate processing, then ease of operation is improved, but adhesion of polymeric binder materials deteriorates
Solution Approach 1:
The patent removes the fiber surface finish through washing or chemical treatment to eliminate the barrier between the fiber and polymeric binder, thereby restoring strong adhesion while maintaining processing ease through the use of plasma or corona treatment to prevent static build-up
Solution Approach 2:
The patent introduces plasma or corona treatment as an intermediary process that modifies the fiber surface to create a state of high surface energy, which serves as an ideal intermediate state for both ease of processing and strong binder adhesion
2Strength
If plasma or corona treatment is applied to enhance surface energy, then adhesion strength is improved, but shelf life deteriorates due to treatment decay
Solution Approach 1:
The patent applies plasma or corona treatment immediately before composite fabrication to ensure the fiber surface is in the optimal high-energy state for adhesion, accepting the temporary nature of the treatment and planning the fabrication process accordingly
Solution Approach 2:
The patent changes the surface energy parameter of the fiber through plasma or corona treatment, creating a temporary but highly effective state for adhesion that is utilized immediately in the fabrication process
3Duration of action of stationary object
If protective coating is applied to preserve surface treatment, then shelf life is improved, but fiber clumping occurs interfering with fiber spreading
Solution Approach 1:
The patent uses a sacrificial fiber surface finish that can be easily removed and reapplied, serving as a temporary protective measure during storage that does not interfere with the ultimate adhesion to polymeric binders
Solution Approach 2:
The patent applies different properties to different parts of the fiber: the core fiber maintains its natural properties for adhesion, while a localized fiber surface finish is applied to the surface to prevent clumping during storage and handling
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 process ensures enhanced fiber bonding, maintains surface energy over time, and prevents fiber clumping, enabling the production of high-quality ballistic-resistant composites with improved uniformity and shelf life.
Implementation Method 1
the fiber surfaces may be treated with various surface treatments, such as a plasma treatment or a corona treatment, to enhance the surface energy at the fiber surfaces
Implementation Method 2
the fiber surfaces may be treated with various surface treatments, such as a plasma treatment or a corona treatment, to enhance the surface energy at the fiber surfaces
Data Source
Figure 1~2
Figure 3A~4B
Figure 5~6
AI summary
Processes for preparing ultra-high molecular weight polyethylene fibers, and the fibers and articles produced therefrom. Exposed surfaces of the fibers are subjected to a treatment that enhances the surface energy at the fiber surfaces. Such treated surfaces are subsequently coated with a protective coating immediately after the treatment to increase the shelf life of the treatment. The coating comprises at least one poly(alkyl-oxide) polymer.