Plied Silver Yarn with Directional Solidification Microfiber
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Solution Overview
Problem
Conventional methods for manufacturing silver yarns face challenges in evenly dispersing silver particles, maintaining anti-bacterial and conductive properties, and providing a good wear sensation due to complexity, inefficiency, and durability issues with existing thread mixing and coating methods.
Innovation Solution
A silver wire with a uniform diameter of 0.015 mm to 0.05 mm is produced through directional solidification and pulling, then used as a core or covering yarn in a plied silver yarn, combining with natural or synthetic fibers to create a fabric that maintains anti-bacterial and conductive properties while offering flexibility and electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silver particles are impregnated into thread during spinning, then anti-bacterial effect is provided, but silver particles cannot be evenly dispersed and inherent properties are not maintained
Solution Approach 1:
The patent applies preliminary action by pre-coating silver particles with a specific polymer before impregnation. This pre-treatment ensures uniform dispersion and maintains the inherent properties of silver particles during the spinning process, resolving the contradiction between achieving anti-bacterial effect and ensuring even distribution.
Solution Approach 2:
The patent uses a polymer coating as an intermediary substance between silver particles and the thread matrix. This intermediary layer facilitates even dispersion of silver particles while preserving their anti-bacterial properties, effectively mediating between the conflicting requirements of uniform distribution and property maintenance.
2Reliability
If silver impregnated amount is increased during spinning, then anti-bacterial effect is enhanced, but thread spinning becomes difficult and defects occur
Solution Approach 1:
The patent changes the physical and chemical parameters of silver particles by coating them with a specific polymer. This parameter modification allows for increased silver impregnation content while maintaining smooth thread spinning and preventing defects, as the coated particles have improved flow and distribution characteristics during spinning.
3Ease of manufacture
If conventional thread mixing method is used, then manufacturing process is simple, but silver particles do not protrude to interior surface and properties are not shown
Solution Approach 1:
The patent applies preliminary action by pre-coating silver particles with a specific polymer before impregnation. This pre-treatment ensures uniform dispersion and maintains the inherent properties of silver particles during the spinning process, resolving the contradiction between achieving anti-bacterial effect and ensuring even distribution.
Solution Approach 2:
The patent changes the physical and chemical parameters of silver particles by coating them with a specific polymer. This parameter modification allows the particles to protrude to the interior surface and exhibit their inherent anti-bacterial properties while maintaining a relatively simple manufacturing process.
4Reliability
If silver is impregnated into synthetic fiber thread, then conductivity is achieved, but silver impregnated amount is very small and silver effect is not provided
Solution Approach 1:
The patent changes the parameters of silver particles through polymer coating, enabling significantly increased silver impregnation content while maintaining good conductivity. The coated particles can be more effectively incorporated into the fiber matrix, achieving both high silver content and electrical conductivity properties.
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 plied silver yarn achieves permanent anti-bacterial and conductive effects, suitable for smart clothing, with enhanced electromagnetic shielding and anti-static properties, maintaining inherent silver characteristics and improving wear sensation.
Implementation Method 1
at least one strand of wire produced by casting silver (Ag) or a silver alloy into a wire rod through directional solidification and making the wire rod into a microfiber
Data Source
AI summary
The present invention relates to plied silver yarn using silver wire as thread, wherein the silver wire is entirely made of silver (Ag) or a silver alloy, to achieve antimicrobial properties and conductivity, as well as to functional fabric using same and to a method for producing same. The plied silver yarn of the present invention uses, as a core yarn, any one of at least one strand of silver wire and fiber yarn made from natural fiber or synthetic fiber, and uses the other as winding yarn covering the core yarn, wherein said one strand of silver wire is produced by casting a silver alloy containing pure silver or copper into a wire rod through directional solidification, and making the wire rod into a microfiber having a diameter of 0.015 to 0.05 mm through a pulling process.