Multifilament Braid with Uniform Crystalline Structure
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Solution Overview
Problem
Conventional ultra high molecular weight polyethylene fibers used in multifilaments and braids exhibit poor dimensional stability and abrasion resistance, leading to issues such as dimensional changes and reduced flexibility over time, especially in applications like fishing lines and blind cords, which affects their performance and longevity.
Innovation Solution
A multifilament and braid are developed with a uniform crystal structure and specific processing methods, including gel spinning, to achieve high strength, high elastic modulus, and improved abrasion resistance, characterized by a high intrinsic viscosity, controlled thermal stress, and thermal shrinkage, ensuring stability across a wide temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyethylene fibers with improved strength and elastic modulus are used, then high strength and high elastic modulus are achieved, but abrasion resistance becomes poor
Solution Approach 1:
The invention changes the microstructure parameters of the fiber by controlling the gel spinning process to achieve a uniform crystalline structure with specific crystal orientation. This results in fibers with both high strength and high abrasion resistance, resolving the contradiction between strength improvement and abrasion resistance deterioration
Solution Approach 2:
The invention creates a composite structure within the fiber by forming a uniform crystalline phase distributed throughout the matrix, achieving a microstructure that simultaneously provides high strength and high abrasion resistance, thus resolving the contradiction between these two properties
2Strength
If polyethylene fibers with improved strength and elastic modulus are used, then high strength and high elastic modulus are achieved, but dimensional stability becomes poor
Solution Approach 1:
The invention changes the microstructural parameters by controlling crystallization during gel spinning to achieve a uniform crystal structure with consistent orientation throughout the fiber. This uniform microstructure provides both high strength and excellent dimensional stability, resolving the contradiction between strength improvement and dimensional stability deterioration
3Stability of the object's composition
If a braid is subjected to heat treatment to suppress mechanical property fluctuation, then mechanical property stability is improved, but abrasion resistance and throwing property deteriorate
Solution Approach 1:
The invention performs preliminary action by creating a uniform crystalline microstructure during the fiber production process itself, rather than relying on post-production heat treatment. This preliminary structuring provides both mechanical property stability and maintains abrasion resistance, resolving the contradiction between stability improvement and abrasion resistance deterioration
Solution Approach 2:
The invention changes the microstructural parameters during fiber formation to achieve optimal crystal orientation and uniformity, which inherently provides mechanical property stability without requiring heat treatment that would compromise abrasion resistance
4Volume of moving object
If the number of fibers for braiding is reduced to narrow rope diameter, then rope diameter is reduced, but abrasion resistance becomes poor
Solution Approach 1:
The invention changes the quality parameters of individual fibers by achieving a uniform crystalline microstructure with high strength and high abrasion resistance. This allows fewer fibers to be used while maintaining adequate abrasion resistance, thus enabling narrower rope diameters without sacrificing reliability
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 multifilament and braid demonstrate enhanced dimensional stability and abrasion resistance, significantly improving their performance and lifespan in various industrial and commercial applications, including fishing lines, blind cords, and other textile products.
Implementation Method 1
ultra high molecular weight polyethylene fibers produced by a production method involving extruding a polyethylene solution obtained by dissolving an ultra high molecular weight polyethylene in an organic solvent by an extruder, thereafter quenching the resulting solution to form a fibrous gel body, and continuously drawing the gel body while removing the organic solvent from the gel body (hereinafter, referred to as gel spinning method)
Implementation Method 2
the multifilament contains polyethylene having an intrinsic viscosity [η] of 5.0 dL/g or more and 40.0 dL/g or less and substantially including ethylene as a repeating unit
Implementation Method 3
continuously drawing the gel body while removing the organic solvent from the gel body
Implementation Method 4
Patent Document 4 describes a cord obtained by subjecting a braid to a heat treatment after production of the braid. The heat treatment can suppress the cord from being fluctuated in mechanical properties.
Data Source
AI summary
It is provided that a multifilament and a braid that are capable of being processed into products in a wide range of temperature and are excellent in dimensional stability and abrasion resistance. A multifilament comprising 5 or more monofilaments, wherein the multifilament contains polyethylene having an intrinsic viscosity [η] of 5.0 dL/g or more and 40.0 dL/g or less and substantially including ethylene as a repeating unit, and shows 1000 times or more in number of reciprocating abrasions at break in an abrasion resistance test measured at a load of 5 cN/dtex in accordance with JIS L-1095.