Polymerizable composition for bonding fibre units
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Solution Overview
Problem
Conventional methods for bonding fiber units, such as sewing threads, face issues with uneven distribution and application of bonding agents, leading to defects like cratering and reduced mechanical strength, especially when using aqueous polymer dispersions which require high energy for drying and can be unsuitable for thermally unstable yarns.
Innovation Solution
A polymerizable composition comprising a prepolymer with multiple vinylidene groups, a photoinitiator, and a compound with a specific weight-average molecular weight, applied without solvents or water, which undergoes photopolymerization to ensure uniform bonding and high mechanical strength without thermal drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aqueous polymer dispersions are used for bonding fiber units, then adhesion between filaments is improved, but high energy consumption and thermal damage to heat-sensitive materials occur due to required drying temperatures
Solution Approach 1:
The invention changes the curing mechanism from thermal to photopolymerization. Instead of using heat to evaporate water and activate bonding, the composition uses photopolymerizable vinylidene groups that cure upon irradiation with UV or visible light. This parameter change eliminates the need for high-temperature drying while maintaining strong adhesion between filaments.
Solution Approach 2:
The invention replaces the thermal drying mechanism with a photopolymerization mechanism. The thermal energy system (heating and evaporation) is substituted with a photochemical system where photoinitiators absorb light energy to generate radicals that trigger polymerization and bonding of the fiber units.
2Strength
If aqueous polymer dispersions are applied to bond fiber units, then bonding is achieved, but uneven distribution and polymer migration to surface cause defects like cratering and reduced mechanical strength
Solution Approach 1:
The invention changes the chemical structure of the bonding agent from aqueous polymer dispersion to a photopolymerizable composition with vinylidene groups. This parameter change allows the composition to remain mobile during application for uniform distribution, then固化 upon irradiation to provide strong bonding without the migration and cratering issues associated with aqueous systems.
Solution Approach 2:
The invention applies the photopolymerizable composition to the fiber units before irradiation, allowing uniform distribution throughout the yarn structure. The composition remains in a mobile state during application, enabling it to penetrate and distribute evenly, then cures in place upon irradiation to provide uniform bonding throughout the entire yarn cross-section.
3Strength
If high application quantities of bonding agent are used to ensure adequate bonding, then adhesion is improved, but surface defects and processing difficulties increase
Solution Approach 1:
The invention changes the composition from aqueous polymer dispersion to a photopolymerizable system with lower viscosity and better penetration characteristics. This allows higher application quantities to be uniformly distributed throughout the yarn without surface pooling or cratering, and the photopolymerization process ensures complete utilization of the bonding agent throughout the yarn cross-section.
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 provides a bonding process that eliminates cratering, enhances mechanical strength, and allows for higher application quantities, ensuring stable yarns with improved sewing properties and reduced energy consumption, while being suitable for heat-sensitive materials.
Implementation Method 1
at least one photoinitiator, and at least one compound with at least one polymerizable vinylidene group
Data Source
Figure 1A~2
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AI summary
The present invention relates to a polymerizable composition for bonding fiber units, in particular linear textiles such as filaments, yarns, threads, or ropes, comprising at least one prepolymer with at least two polymerizable vinylidene groups, such as a polyurethane with at least two (meth)acrylate groups, at least one photoinitiator, and at least one compound with at least one polymerizable vinylidene group having a weight-average molecular weight of 70–800 g/mol. The present invention further relates to a method for bonding fiber units, comprising applying the composition according to the invention to at least one fiber unit, such as a filament, yarn, thread, or rope, and irradiating the fiber unit thus obtained with radiation of a wavelength in the range of, for example, 100–450 nm.