Recyclable Cooling Fabric Using Phase Change Material Coating
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Solution Overview
Problem
Existing cooling fabrics rely on non-biodegradable synthetic materials, leading to environmental concerns due to their persistence in landfills.
Innovation Solution
A recyclable cooling fabric is developed, comprising face yarns made of polyethylene, nylon, and recycled polyester, with inlay yarns of virgin or recycled polyester, wool, or polyethylene, and optionally coated with a phase change material, to provide cooling properties while being environmentally friendly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling fabrics are made from synthetic materials, then cooling properties are achieved, but environmental friendliness deteriorates due to non-biodegradability
Solution Approach 1:
The patent changes the material composition parameters by using recycled polyester instead of virgin synthetic materials, maintaining the cooling properties while improving environmental compatibility. The fabric structure and thermal properties are optimized to achieve effective cooling with recyclable materials.
Solution Approach 2:
The patent incorporates recycled polyester materials into the fabric construction, recovering post-consumer or post-industrial plastic waste and transforming it into functional cooling fabric. This approach maintains cooling performance while addressing environmental concerns through material recovery and reuse.
2Object-affected harmful factors
If recycled materials are used, then environmental friendliness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies different material compositions to different layers of the fabric - face yarns contain recycled polyester mixed with other fibers for cooling, while inlay yarns provide structural support. This localized quality approach allows recycling in critical cooling zones without compromising overall fabric integrity or requiring complete reconstruction of the manufacturing process.
Solution Approach 2:
The patent creates composite yarns combining recycled polyester with other fibers (nylon, polyethylene, wool) to achieve both cooling properties and structural requirements. These composite materials integrate recycled content into multi-functional yarns that simplify manufacturing by combining multiple functions in single components.
3Temperature
If phase change material is coated on fabric, then cooling effectiveness is enhanced, but fabric weight increases
Solution Approach 1:
The patent optimizes the phase change material coating parameters including thickness, composition, and application method to achieve effective cooling with minimal weight addition. The coating is applied at controlled levels to provide sufficient thermal regulation without excessive weight gain.
Solution Approach 2:
The patent uses thin film coatings of phase change material applied to the fabric surface, providing cooling functionality through a minimal mass layer. This thin-film approach delivers effective thermal regulation while adding minimal weight compared to bulk cooling materials.
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 fabric achieves effective cooling while being recyclable and environmentally friendly, with thermal effusivity ranging from 85 to 1600 Ws1/2/m2K and a fabric weight from 200 to 450 GSM.
Implementation Method 1
the recyclable cooling fabric may further comprise a phase change material coated on at least one of the first surface and the second surface of the recyclable cooling fabric
Data Source
AI summary
A recyclable cooling fabric is provided. The recyclable cooling fabric includes a first surface and a second surface opposite the first surface. The first surface and the second surface include a plurality of face yarns. The plurality of face yarns includes polyethylene, nylon, and recycled polyester. A plurality of inlay yarns is disposed between the first surface and the second surface. Methods of manufacturing the recyclable cooling fabric, and mattresses utilizing the recyclable cooling fabric as mattress ticking are also provided.