Spunbonded Fabric with High Additive Content via Solution Spinning
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Solution Overview
Problem
Existing textile fabrics with functional additives face challenges in achieving high particle content without additional processing steps, leading to reduced functionality and mechanical resistance due to frequent fiber breaks during spinning, and require separate production processes that damage fibers.
Innovation Solution
A spunbonded nonwoven process using a solution of non-fusible polymers doped with functional additives, allowing for continuous production of fibers with over 40% weight content of additives, achieving stable and reproducible textile fabrics with high self-binding capacity through entanglement and varying diameters, eliminating the need for additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If functional additives are incorporated into fibers at high concentration (>40% by weight), then functionality is improved, but fiber stability deteriorates due to frequent breaks during spinning
Solution Approach 1:
The patent changes the physical state of the polymer from solid to solution form, allowing functional additives to be dissolved at high concentrations (>40% by weight) without causing fiber breaks during spinning. The solution spinning process enables stable fiber formation with high additive content by controlling the physical-chemical parameters of the spinning solution.
Solution Approach 2:
The patent creates composite fibers by incorporating functional additives (such as zinc white, titanium dioxide, or other functional particles) into polymer solutions during the spinning process. These composite fibers maintain structural integrity while achieving high functional additive content through the composite structure of polymer matrix + functional particles.
2Quantity of substance
If separate production processes are used to create functional fibers, then functionality is improved, but manufacturing complexity increases and fibers are damaged
Solution Approach 1:
The patent merges the fiber formation process with the functional additive incorporation process into a single solution spinning operation. Instead of producing plain fibers first and then adding functional additives through separate processes, the functional additives are incorporated during the spinning itself, simplifying the overall manufacturing process while maintaining high functionality.
Solution Approach 2:
The patent performs the functional additive incorporation action during the spinning process itself, before the fibers are formed into the final textile product. This preliminary action of adding functional additives during spinning eliminates the need for subsequent separate functionalization processes, reducing manufacturing complexity and avoiding fiber damage from multiple processing steps.
3Quantity of substance
If fiber diameter is reduced to accommodate functional particles, then particle content is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent changes the approach from reducing fiber diameter to increasing fiber diameter variability. By allowing diameter fluctuations of at least 30% within and between fibers, the process can accommodate high functional particle content (40% or more) while maintaining mechanical strength through the natural variation in fiber dimensions rather than uniform thinning.
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 fabric exhibits permanent functionality and enhanced mechanical resistance, suitable for direct use or further processing, with functional properties like electrical conductivity, absorbency, and temperature regulation, achievable without additional coating or surface finishing steps.
Implementation Method 1
continuous production of fibers with over 40% weight content of additives, achieving stable and reproducible textile fabrics
Implementation Method 2
achieving stable and reproducible textile fabrics with high self-binding capacity through entanglement and varying diameters
Data Source
AI summary
The invention relates to a highly functional spunbonded fabric made from fibres based on non-fusible polymers, which contain one or more functional additives. The fibres are interwoven and interlocked, are of different lengths having aspect ratios above 1.000 and form a firm fleece composite. Said fibres have a mean diameter of 0.1 to 500 micrometres and diameter variations within a fibre and/or among each other of at least 30%. In addition to the non-fusible polymers, the fibres contain, based on the total weight thereof, more than 40 wt % of functional additives in solid and/or liquid form, wherein the functional additives are finely distributed in the fibres. The spunbonded fabric is produced from a spinning solution that contains the non-fusible polymer dissolved in a direct solvent, and at least one functional additive. The spinning solution is pressed out of a spinneret, and the resulting polymer strands are drawn in the longitudinal direction to form filaments or fibres, stabilised and laid down to form a fleece fabric. The spunbonded fabrics can be used, for example, to produce clothing, technical textiles or as filters.