Nanofiber Composite False Twist Yarn Slitting and Bonding
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Solution Overview
Problem
Conventional nanofiber-based composite yarns face issues with continuity and process loss during slitting and twisting, limiting their industrial application due to poor handling and physical properties.
Innovation Solution
A method involving electrospinning to produce nanofiber webs, followed by laminating, primary slitting, bonding, and secondary slitting to create a nanofiber tape yarn, which is then twisted or composite-twisted with natural or synthetic fibers to enhance strength and continuity, allowing for continuous processing and improved physical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If nanofiber webs are used directly, then high porosity and large surface area are achieved, but handling properties and physical strength deteriorate
Solution Approach 1:
The patent combines nanofibers with conventional fibers (synthetic or natural) to create composite yarns. The nanofibers provide high porosity and surface area, while the conventional fibers contribute tensile strength and handling properties, resolving the contradiction between porosity and strength.
Solution Approach 2:
The patent changes the physical state and properties of nanofibers through electrospinning parameters control, producing nanofibers with optimized diameter (50-500 nm) and morphology that balance porosity with improved mechanical properties when combined with other fibers.
2Area of moving object
If nanofiber webs are used directly, then large surface area is achieved, but handling properties deteriorate
Solution Approach 1:
By combining nanofibers with conventional fibers having good handling properties, the composite yarn maintains the large surface area advantage of nanofibers while gaining the ease of operation and handling characteristics of conventional fibers.
3Productivity
If conventional spinning process is used, then continuous production is achieved, but fiber diameter cannot be reduced below 1 μm
Solution Approach 1:
The patent replaces the conventional mechanical spinning process with electrospinning, which uses electrical fields instead of mechanical forces to form nanofibers. This substitution enables continuous production of nanofibers with diameters below 1 μm, achieving both continuous productivity and precise nanoscale fiber diameter control.
Solution Approach 2:
The patent changes the fundamental production method from mechanical spinning to electrospinning, altering the physical parameters (applying high voltage electric fields) to achieve nanoscale fiber diameters while maintaining continuous production capability.
4Quantity of substance
If nanofiber-only yarns are produced, then high porosity is maintained, but strength and elasticity deteriorate
Solution Approach 1:
The patent creates composite yarns by combining nanofibers with conventional fibers. The nanofibers maintain high porosity while the conventional fibers provide the necessary strength and elasticity, resolving the contradiction between porosity and mechanical properties.
5Manufacturing precision
If slitting and twisting processes are performed separately, then manufacturing precision is maintained, but productivity deteriorates
Solution Approach 1:
The patent combines multiple processing steps (electrospinning, drying, and winding) into an integrated continuous process. The electrospun nanofiber web is dried and wound onto a drum in a continuous manner, eliminating interruptions and improving productivity while maintaining precision through controlled processing parameters.
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 enables continuous production of nanofiber-based composite false twist yarns with enhanced strength, elasticity, and porosity, expanding their use in industrial applications by improving handling and physical properties through heat fixation and fusion with existing materials.
Implementation Method 1
The electrospinning technique involves applying a high voltage to a polymer solution or melt and spraying the polymer solution onto a charged surface with a negative pole or earth, during which a solvent is volatized while nanofiber shaped materials are manufactured by being laminated in a web or non-woven state.
Implementation Method 2
applying a high voltage to a polymer solution or melt and spraying the polymer solution onto a charged surface with a negative pole or earth, during which a solvent is volatized while nanofiber shaped materials are manufactured
Data Source
AI summary
Provided is a nanofiber based composite false twist yarn that is obtained by producing a nanofiber tape yarn by precisely slitting a nanofiber membrane produced by electrospinning and then twisting a nanofiber-only twist yarn that is obtained by twisting the nanofiber tape yarn or composite-twisting a nanofiber-only twist yarn and a natural fiber or synthetic fiber. The nanofiber based composite false twist yarn includes: a nanofiber tape yarn including at least one bonding portion or a false twist yarn which is obtained by false twisting the nanofiber tape yarn; and a natural fiber yarn or a synthetic fiber yarn that is composite-false-twisted with the nanofiber tape yarn or the false twist yarn, wherein the nanofiber tape yarn is made of a nanofiber web that is obtained by integrating polymer nanofibers made of a fiber-forming polymer material and having an average diameter of less than 1 μm thereby having fine pores.