Plant-Based Polyester Filament With Uniform Extract Dispersion
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Solution Overview
Problem
Existing polyester fibers face issues such as changes in properties when mixed with functional materials, poor compatibility, agglomeration of plant extracts, oxidation at high temperatures, and poor peelability during spinning, leading to production challenges and shortcomings like pilling, static electricity, and dust sticking.
Innovation Solution
A method involving the use of a plant-based functional polyester filament prepared by adding specific ratios of antioxidants, dispersants, protective agents, and modifiers to molten PET, followed by extrusion to create a masterbatch, which is then spun into filaments, ensuring uniform dispersion and prevention of agglomeration and carbonization of plant extracts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If plant extracts are directly added to molten PET, then the polyester fiber gains plant functionality, but the plant extracts agglomerate and are unevenly dispersed
Solution Approach 1:
The patent introduces a plant extract masterbatch as an intermediary carrier. The masterbatch contains plant extracts pre-dispersed in a carrier resin, which acts as a mediator between the plant extract and molten PET. This intermediary system enables uniform distribution of plant extracts throughout the polyester fiber during the spinning process, eliminating direct addition problems while maintaining functional benefits.
2Adaptability or versatility
If plant extracts are directly added to molten PET, then the polyester fiber gains plant functionality, but the plant extracts are easily oxidized at high temperature
Solution Approach 1:
The patent applies preliminary action by pre-mixing plant extracts with carrier resin and antioxidants in a masterbatch before the actual fiber spinning process. This preliminary preparation allows antioxidants to be already positioned around plant extract molecules, providing immediate protection against oxidation when the masterbatch is subsequently incorporated into molten PET during high-temperature processing.
3Adaptability or versatility
If plant extracts are added to PET, then the polyester fiber has functional properties, but the melt produces expansion region affecting shape and causes sticking-to-plate phenomenon
Solution Approach 1:
The patent utilizes parameter changes by carefully controlling the concentration of plant extracts in the masterbatch and adjusting processing parameters such as temperature and shear rate during spinning. By optimizing these parameters, the patent suppresses the expansion region formation in the melt while maintaining the functional properties of plant extracts in the final fiber product.
4Adaptability or versatility
If plant extracts are added to PET, then the polyester fiber has functional properties, but the original properties of polyester fiber are changed
Solution Approach 1:
The patent applies local quality by concentrating plant extracts in specific regions through the masterbatch system rather than uniform distribution. The carrier resin creates localized zones containing plant extract functionality, allowing the bulk polyester fiber to maintain its original mechanical and physical properties while specific local regions provide the desired functional characteristics.
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 filament exhibits high mechanical strength, antibacterial performance, wear resistance, and anti-mite properties, with improved peelability and prevention of static electricity and dust sticking, meeting standards for non-pilling and anti-static performance.
Implementation Method 1
the plant extracts are directly added to molten polyethylene terephthalate (PET). The plant extracts tend to agglomerate and are unevenly dispersed in the molten PET
Implementation Method 2
The plant extracts tend to agglomerate and are unevenly dispersed in the molten PET, and are easily oxidized at a high temperature
Implementation Method 3
adding a protective agent and a plant extract to the molten PET, stirring the molten PET at a high speed, adding a modifier to the molten PET, obtaining a mixture by uniformly mixing the molten PET, and performing an extrusion granulation process on the mixture
Data Source
AI summary
A plant-based functional polyester filament and a preparation method of the plant-based functional polyester filament are provided. The plant-based functional polyester filament includes polyester, and plant extract in a weight percentage range of approximately 0.1%-1.5%. The plant extract includes one or more of a peppermint extract, a valerian extract, a lavender extract, a wormwood extract, a chitin extract and a seaweed extract. The method includes preparing a plant-based functional polyester masterbatch, including: heating polyethylene terephthalate (PET) chips to a molten state, adding an antioxidant and a dispersant to the molten PET, stirring the molten PET, adding a protective agent and a plant extract to the molten PET, stirring the molten PET at a high speed, adding a modifier to the molten PET, obtaining a mixture by uniformly mixing the molten PET, and performing an extrusion granulation process on the mixture.