Multifunctional Polyester Fiber Thermal Insulation
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Solution Overview
Problem
Conventional polyester fibers face challenges in achieving excellent thermal storage, insulation, and far-infrared emission properties while maintaining high spinning processability and dyeability, particularly due to issues with particle dispersibility and color limitations in existing technologies.
Innovation Solution
A method involving the melt-mixing of cesium tungsten oxide-based composite metal oxide particles with polyester to create a master batch chip, which is then spun using a specialized nozzle to form a hollow fiber with excellent thermal insulation and far-infrared emission properties, ensuring high fineness and dyeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zirconium carbide particles are incorporated into blended yarns to provide thermal storage and insulation properties, then thermal storage and insulation properties are improved, but color variety is limited due to gray or black color of particles
Solution Approach 1:
The patent changes the chemical composition parameter of the ceramic particles from zirconium carbide to cesium tungsten oxide, which fundamentally alters the optical properties. This parameter change enables the particles to maintain their thermal storage and insulation functions while achieving excellent whiteness and far-infrared emission properties, thereby resolving the color limitation without sacrificing thermal performance
Solution Approach 2:
The patent uses composite ceramic particles consisting of cesium tungsten oxide as a multifunctional additive that combines thermal storage, insulation, and far-infrared emission capabilities. This composite material approach allows achieving multiple functions (thermal storage, insulation, whiteness, and far-infrared emission) simultaneously, overcoming the color limitation of conventional zirconium carbide particles
2Reliability
If a large amount of ceramic particles is added to polyester to improve thermal properties, then thermal storage and insulation properties are improved, but dispersibility deteriorates making filament production difficult
Solution Approach 1:
The patent optimizes the particle size parameter of cesium tungsten oxide to 1-800 nm, which is significantly smaller than conventional ceramic particles. This parameter change enables better dispersion of particles within the polyester matrix while maintaining thermal storage and insulation properties, thereby facilitating filament production without aggregation issues
Solution Approach 2:
The patent employs a master batch preparation step as an intermediary process where ceramic particles are first uniformly dispersed in a carrier resin to create a master batch, which is then mixed with polyester chips. This intermediary approach ensures uniform distribution of ceramic particles throughout the polyester, preventing aggregation and enabling successful filament production while maintaining thermal properties
3Reliability
If tungsten oxide particles are used to provide thermal properties, then thermal storage properties are improved, but particle aggregation occurs causing poor spinnability and appearance defects
Solution Approach 1:
The patent changes the particle size parameter of tungsten oxide to a specific range of 1-800 nm and controls the distribution of particle sizes. This parameter change prevents particle aggregation during processing while maintaining thermal storage properties, thereby improving spinnability and eliminating appearance defects such as fluffs or loops
Solution Approach 2:
The patent creates local quality differences by using a core-shell structure or selective distribution of ceramic particles within the fiber cross-section. This allows concentrating ceramic particles in specific regions to maximize thermal storage function while maintaining good spinnability and avoiding aggregation in critical areas, thereby resolving the contradiction between thermal performance and manufacturing ease
4Productivity
If fiber fineness is reduced to achieve high multifilament yarn with single-yarn fineness of 1 denier or less, then yarn fineness is improved, but maintaining particle dispersibility and thermal properties becomes more difficult
Solution Approach 1:
The patent reduces the particle size parameter of cesium tungsten oxide to 1-800 nm, which enables better dispersion in fine yarns with single-yarn fineness of 1 denier or less. This parameter change ensures that even in high-multifilament yarns, particles remain uniformly distributed without aggregation, maintaining thermal storage and insulation properties while achieving the desired yarn fineness
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 multifunctional polyester fiber exhibits excellent thermal storage, insulation, and far-infrared emission properties, along with improved spinning processability and dyeability, making it suitable for high-value applications.
Implementation Method 1
exhibiting excellent spinning processability and yarn processability... excellent far-infrared emission properties
Implementation Method 2
excellent thermal storage and insulation properties
Implementation Method 3
cooling the spun fiber using a cooling device including a rotational outflow quenching unit
Data Source
AI summary
The present invention relates to a method for producing a multifunctional polyester fiber, including: mixing a polyester master batch chip, containing cesium tungsten oxide-based particles, with a general polyester chip; spinning the mixture to form a spun fiber; and cooling the spun fiber using a cooling device having a rotational outflow quenching unit and a nozzle-warming heater, and to a fiber produced by the method. The multifunctional polyester fiber according to the present invention exhibits excellent far-infrared emission properties, thermal storage/insulation properties, spinning processability, and dyeability.