Article with reactive metals bound to its surface and method of application
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Solution Overview
Problem
Existing methods for incorporating reactive metals into fabrics, such as extrusion and electroplating, are limited in their ability to treat woven or non-woven textiles in their finished form, are sensitive to chemicals, and result in fabrics that are clingy, static, and limited in color options, while also being costly and environmentally unfriendly.
Innovation Solution
A method using a polymeric carrier suspension comprising polymers synthesized from acrylic acids, methylacrylates, and urethanes, with reactive metals like zinc and copper, applied to substrates through a dye-bath or pad trough process, allowing for the time-release of metal ions and providing a wide range of colors without the need for electric current or excessive chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If extrusion method is used to incorporate metals into fabrics, then metals can be encapsulated within the fiber, but the method cannot treat woven or nonwoven textiles in their finished form and the fibers are sensitive to chemicals
Solution Approach 1:
The patent applies metal ions to the fabric surface before the fabric is used, rather than incorporating metals during fiber manufacturing. This preliminary application allows treatment of finished woven or nonwoven textiles without requiring modification of the fiber production process, resolving the contradiction between chemical sensitivity and applicability to finished textiles.
Solution Approach 2:
The patent uses an intermediary metal ion application process that deposits metal ions onto the fabric surface without requiring the fabric to be chemically sensitive. This intermediary approach allows metal incorporation into finished textiles while maintaining the original fabric's chemical properties.
2Ease of manufacture
If electroplating is used to apply metals to fabrics, then metals can be deposited on the fabric surface, but the process requires a conductive material and electric current
Solution Approach 1:
The patent replaces the electroplating process (which requires electric current and conductive materials) with a metal ion application process that uses no electric current. This substitution simplifies the manufacturing process by eliminating complex electrical equipment while still achieving metal deposition on fabric surfaces.
Solution Approach 2:
The patent employs a self-service metal ion application process where metal ions are applied to the fabric without requiring external electric current or complex plating equipment. The process uses the fabric's own properties to accept and retain metal ions, eliminating the need for additional conductive materials and electrical systems.
3Reliability
If metals are incorporated into fabrics using conventional methods, then antimicrobial properties are achieved, but the fabrics become clingy, static, and limited in color options
Solution Approach 1:
The patent applies metal ions locally to the fabric surface rather than incorporating them throughout the entire fiber structure. This localized application maintains the fabric's original comfort properties and color options while providing antimicrobial protection at the surface where it is most needed.
Solution Approach 2:
The patent changes the physical state of metal incorporation from bulk integration (which causes clinginess and static) to surface deposition of metal ions. This parameter change allows the fabric to maintain its original comfort and color properties while still providing antimicrobial functionality through the surface-applied metal ions.
4Reliability
If electroplating or extrusion methods are used to apply metals to fabrics, then metal incorporation is achieved, but the process is costly and environmentally unfriendly
Solution Approach 1:
The patent uses a disposable metal ion application process that does not require expensive, complex equipment like electroplating machines. The process uses simple, inexpensive metal ion solutions that can be applied and then discarded, eliminating the need for costly infrastructure while still achieving effective metal incorporation.
Solution Approach 2:
The patent converts the potential harm of complex, expensive manufacturing processes into benefit by using a simple, environmentally friendly metal ion application method. The process eliminates harmful chemicals and expensive equipment requirements while maintaining effective metal incorporation, turning the limitation of simplicity into an environmental and economic advantage.
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 the production of lightweight, comfortable, and environmentally conscious metal-infused fabrics that can be woven, non-woven, or knitted, with improved opacity and color options, while maintaining the physical properties of the substrate and allowing for the transport of metal ions, thus enhancing their antimicrobial and antistatic properties.
Implementation Method 1
reactive metals bound to its surface
Implementation Method 2
time release of metal ions from the surface of the article
Data Source
AI summary
A polymeric carrier composition including a polymer synthesized from monomers selected from acrylic acids, methylacrylates and urethanes and at least one metal having an oxidation state of +1 or +2, including salts and coordination complexes thereof. The composition may be a suspension having 0.5 to 10% by weight of the polymer prepared from monomers selected from a group consisting of acrylic acids, methylacrylates and urethanes, and a viscosity less than 1,000 cps. The composition is applied to substrates, such as woven fabrics, to create metal-infused articles.