Multi-Layer Coated Staple Fiber for Buoyant Heat-Insulated Padding

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Solution Overview

Problem

Natural staple fibers used for padding, such as wool, cotton, and kapok, exhibit hygroscopic properties leading to water absorption and flammability, compromising their buoyancy and heat insulation performance.

Innovation Solution

A coated staple fiber is developed with a core of natural or man-made organic fibers, coated with a hydrocarbon resin base layer, an intermediate layer of aerogel microparticles for heat insulation and fire retardancy, and a top hydrophobic organosilane layer to enhance water repellency and buoyancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If natural staple fibers (wool, cotton, kapok) are used for padding, then heat insulating properties are improved, but water absorption increases and buoyancy deteriorates

Engineering Contradiction:

Improveheat insulationVSAvoidbuoyancy

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent applies composite materials by coating natural staple fibers with a multi-layer coating system comprising a hydrocarbon resin base layer, an intermediate aerogel layer, and a top organosilane hydrophobic layer. This composite structure combines the heat insulating properties of natural fibers with the water repellency of the coating layers, preventing water absorption while maintaining thermal insulation performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by modifying only the outer surface of the natural fibers through coating, while preserving the inner structure and heat insulating properties of the core fiber. The coating layers are applied selectively to the fiber surface to provide water repellency without compromising the bulk thermal insulation characteristics of the natural fiber core.

Inventive Principle:

Principle #3Local quality

2Temperature

If natural staple fibers are used for padding, then heat insulating properties are improved, but fire retardancy deteriorates

Engineering Contradiction:

Improveheat insulationVSAvoidflammability

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by incorporating fire retardant components into the multi-layer coating system. The hydrocarbon resin base layer and organosilane top layer provide fire retardant properties, creating a composite structure that maintains the heat insulating benefits of natural fibers while adding flame resistance to protect against fire hazards.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If natural staple fibers are used for padding, then organic and biodegradable properties are maintained, but water repellency deteriorates

Engineering Contradiction:

ImprovebiodegradabilityVSAvoidwater absorption

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by applying hydrophobic coating layers only to the outer surface of the natural fibers, leaving the core fiber structure intact and potentially biodegradable. The top organosilane layer provides water repellency locally at the fiber surface, preventing water absorption while the core natural fiber maintains its organic and biodegradable characteristics.

Inventive Principle:

Principle #3Local quality

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 coated staple fiber achieves improved heat insulation, buoyancy, and fire retardancy while maintaining flexibility, preventing water penetration and retaining air within the aerogel particles, making it suitable for protective and floating padding.

Implementation Method 1

retaining air within the aerogel particles

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

top hydrophobic organosilane layer to enhance water repellency

Methodology Applied

Scientific EffectHydrophobe: Hydrophobe

Implementation Method 3

intermediate layer of aerogel microparticles for heat insulation

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS11414813B2Coated staple fiber suitable for obtaining heat-insulated and floating paddings, and process for obtaining said fiber

Publication Date: 2022.08.16 PANGAIA MATERIALS SCI LTD

AI summary

A coated staple fiber (1) suitable for obtaining protective and floating padding, having a core consisting of at least one natural and/or man-made organic staple fiber (F) and comprising: I) a base tackifier layer (A) which covers the natural and/or man-made organic staple fiber (F) and which comprises a hydrocarbon resin II) an intermediate heat insulating and fire retardant layer (B) which covers the base layer (A) and which comprises aerogel microparticles evenly but not continuously distributed, III) a top hydrophobic layer (C) which covers the intermediate layer (B) and which comprises organosilanes, wherein the base layer (A) binds the intermediate layer (B) to the natural and/or man-made organic staple fiber (F) and the intermediate layer (B) is included between the base layer (A) and the top layer (C).