Ribbon Yarn with Copolymer Matrix for Improved Filament Adhesion
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Solution Overview
Problem
Existing methods for producing ribbon yarns for airbags face challenges with adhesion of filaments to additives or coatings, particularly with polymers like polyester, leading to suboptimal performance and increased material usage.
Innovation Solution
A method involving the use of multifilament yarns made of polyamide and/or polyester, spread such that not more than five filaments overlap, fixed with a matrix of copolyamides, copolyesters, or silicones, and wound without twist, allowing for improved adhesion and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If yarns are treated with activatable additives or coatings to achieve flat configuration, then the ribbon yarn structure is obtained, but the adhesion of filaments to additives or coatings is insufficient
Solution Approach 1:
The patent applies a preliminary activation treatment to the multifilament yarn before spreading and forming the final ribbon structure. This preliminary action ensures that the activating agent is already present on the filaments when they are spread apart, creating better adhesion conditions before the filaments are fixed in their final positions. The activation step is performed in advance on the bundled yarn, allowing the agent to penetrate and bond with multiple filaments simultaneously.
Solution Approach 2:
The patent spreads the multifilament yarn so that not more than five filaments overlie one another, creating a controlled local distribution where the activating agent can effectively reach and adhere to each filament. This local quality control ensures that no filament is completely obscured by others, allowing uniform adhesion across the entire yarn cross-section while maintaining the flat ribbon configuration.
2Object-affected harmful factors
If woven fabrics are provided with surface coating to achieve heat resistance and seal tightness, then protection is improved, but material expense increases
Solution Approach 1:
The patent uses a composite structure combining multifilament yarn (polyamide and/or polyester) with an activating agent that provides heat resistance and seal tightness properties. The activating agent forms an integrated part of the ribbon yarn structure itself, creating a composite material where the functional properties are built into the yarn rather than added as a separate coating layer, thereby reducing overall material consumption.
Solution Approach 2:
The patent employs a cost-effective activating agent that can be applied in small quantities to provide the necessary heat resistance and seal tightness. The agent is designed to be highly efficient, requiring minimal amounts to achieve the protective function, thus reducing material expense while maintaining adequate protection levels for the airbag application.
3Object-affected harmful factors
If fabric is provided with silicone coating to achieve seal tightness, then gas and particle impermeability is improved, but weight and space requirements increase
Solution Approach 1:
The patent creates a composite ribbon yarn where the activating agent is integrated within the yarn structure itself, forming a lightweight composite material that provides gas tightness without requiring heavy silicone coatings. The multifilament structure combined with the activating agent creates an efficient barrier that is significantly lighter than conventional silicone-coated fabrics while maintaining equivalent gas and particle impermeability.
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
This approach enhances adhesion, reduces material consumption, and provides improved resistance to heat, gas-tightness, and weight reduction, making the ribbon yarns suitable for airbag and tire reinforcement applications.
Implementation Method 1
the adhesion of the filaments to the 'activatable' additives or coatings
Implementation Method 2
a thermoplastic copolyamide, especially preferably a copolyamide with a melting point between 120 and 150° C., is used as the fixing agent
Implementation Method 3
the fixing agent or agents are selected from a group consisting of copolyamides, copolyesters, and silicones
Data Source
AI summary
A method is disclosed for fabricating a ribbon yarn, the method including: spreading the yarn such that not more than five filaments are lying over one another, fixing the yarn by forming a matrix of one or more fixatives, winding the fixed yarn, wherein the fixative or fixatives are selected from a group consisting of copolyamides, copolyesters and silicones and also mixtures or blends thereof. Also described is the ribbon yarn and the application of the ribbon yarns for airbag fabrics, as a tire reinforcement and in textile construction.