NIR Shielding Masterbatch Composition for Functional Textiles

Solution Overview

Problem

Functional textiles face challenges such as poor fastness to washing, reduced air permeability, harsh hand-feel, and instability due to post-treatment of fabrics, and difficulties in modifying polymers to incorporate functional materials effectively, including issues with homogeneity and compatibility of metallic ionic compounds with thermoplastic polymers.

Innovation Solution

A composition comprising a metallic ionic compound powder, a cross-linking agent, a thermoplastic polymer, a cross-linking initiator, and a dispersing agent is used to create a near-infrared shielding masterbatch, where the metallic ionic compound powder is distributed across a cross-linked thermoplastic polymer network, enhancing compatibility and allowing for higher loadings of the metallic ionic compound powder, suitable for spinning processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If functional materials are post-treated onto fabric surfaces, then additional functionality is achieved, but fastness to washing deteriorates and materials tend to fall-off

Engineering Contradiction:

Improveadditional functionalityVSAvoidfastness to washing

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The functional metallic ionic compound powder is incorporated into the polymer matrix during the masterbatch preparation stage, before the actual textile production. This preliminary incorporation ensures the functional material becomes an integral part of the polymer structure, preventing later detachment during washing while maintaining the desired NIR shielding functionality.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention merges the functional metallic ionic compound powder with the thermoplastic polymer into a single integrated masterbatch composition. This combination ensures the functional material and polymer structure become unified, eliminating the separation issue that occurs with post-treatment methods while maintaining both structural integrity and functional performance.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If functional material is physically mixed with polymeric material, then additional functionality is achieved, but homogeneity and stability of the mixture deteriorate

Engineering Contradiction:

Improveadditional functionalityVSAvoidhomogeneity and stability of mixture

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

A dispersing agent is introduced as an intermediary substance to facilitate uniform distribution of the metallic ionic compound powder within the thermoplastic polymer matrix. This dispersing agent acts as a mediator that improves compatibility between the inorganic powder and organic polymer, ensuring homogeneous mixing and stable composition throughout the masterbatch.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention creates a composite masterbatch material that integrates metallic ionic compound powder, thermoplastic polymer, cross-linking agent, and dispersing agent into a unified composite structure. This composite approach leverages the synergistic effects of different materials to achieve both functional performance and compositional stability.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If excessive amount of functional material is added to polymeric material, then desired functionality is enhanced, but original properties of polymeric material deteriorate and spinning becomes inoperable

Engineering Contradiction:

Improvedesired functionalityVSAvoidspinnability

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention optimizes the concentration parameters of the metallic ionic compound powder within the masterbatch to achieve effective NIR shielding functionality while maintaining the thermoplastic polymer's essential properties. By carefully controlling the amount of functional material and using cross-linking to stabilize the structure, the masterbatch remains suitable for spinning processes despite the presence of functional additives.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The functional metallic ionic compound powder is distributed locally and uniformly throughout the polymer matrix rather than being concentrated in one area. This local distribution ensures that sufficient functional material is present to achieve NIR shielding effects while the overall polymer structure and its spinnability are preserved in other regions of the material.

Inventive Principle:

Principle #3Local quality

4Object-affected harmful factors

If metallic ionic compound powder is distributed in thermoplastic polymer, then near-infrared shielding efficacy is improved, but compatibility and homogeneity deteriorate

Engineering Contradiction:

Improvenear-infrared shielding efficacyVSAvoidcompatibility and homogeneity

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

A dispersing agent is introduced as an intermediary substance to facilitate uniform distribution of the metallic ionic compound powder within the thermoplastic polymer matrix. This dispersing agent acts as a mediator that improves compatibility between the inorganic powder and organic polymer, ensuring homogeneous mixing and stable composition throughout the masterbatch.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention creates a composite masterbatch material that integrates metallic ionic compound powder, thermoplastic polymer, cross-linking agent, and dispersing agent into a unified composite structure. This composite approach leverages the synergistic effects of different materials to achieve both functional performance and compositional stability.

Inventive Principle:

Principle #40Composite materials

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 solution achieves improved near-infrared and thermal shielding efficacy while maintaining the spinnability and stability of the masterbatch, with the near-infrared shielding masterbatch exhibiting enhanced performance compared to conventional methods, including reduced temperature rise and improved fiber strength and washing fastness.

Implementation Method 1

the cross-linking agent would cross-link with the molten thermoplastic polymer, whereby the metallic ionic compound powder would distribute across the cross-linked thermoplastic polymer

Methodology Applied

Scientific EffectCross-linking: Chemical Bonding

Implementation Method 2

films and/or fibers that exhibit near-infrared shielding and thermal shielding functionalities

Methodology Applied

Scientific EffectNear-infrared shielding: Absorption (EM radiation)

Data Source

PatentUS9034229B2Composition and process for preparing NIR shielding masterbatch and NIR shielding masterbatch and application thereof

Publication Date: 2015.05.19 TAIWAN TEXTILE RESEARCH INSTITUTE

AI summary

Disclosed herein is a method for preparing a near infrared shielding fiber. The method includes the steps of preparing and compounding a composition, then pelletizing the compounded composition to obtain the near-infrared shielding masterbatch, and melt spinning the near-infrared shielding masterbatch into the near-infrared shielding fiber. The composition includes at least one metallic ionic compound powder in an amount of about 1-25 wt %, a cross-linking agent in an amount of about 0.1-2 wt %, a thermoplastic polymer in an amount of about 67-98.7 wt %, a cross-linking initiator in an amount of about 0.1-1 wt %, and a dispersing agent in an amount of about 0.1-2 wt %.