Surface-Treated High-Tenacity Yarn for Stronger Binder Adhesion
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Solution Overview
Problem
High tenacity fibers used in ballistic composites face a challenge where plasma and corona treatments, intended to improve bonding with surface coatings, often reduce the physical strength of the fibers, leading to decreased ballistic performance and increased backface signature upon projectile impact.
Innovation Solution
A process involving the partial removal of existing fiber surface finishes followed by plasma or corona treatment in a non-vacuum environment, which maintains or even enhances the tenacity of high tenacity fibers while improving bonding with polymeric binder materials, thereby reducing backface signature without compromising ballistic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plasma or corona treatment is applied to improve fiber bonding with surface coatings, then adhesion properties are improved, but physical strength of the fibers is reduced
Solution Approach 1:
The patent applies plasma or corona treatment only to the fiber surface rather than the entire fiber structure. This localized treatment modifies only the outer layer to improve adhesion properties while leaving the bulk fiber strength intact. The surface undergoes chemical changes (introduction of polar groups, increased surface energy) without compromising the internal molecular structure that provides mechanical strength.
Solution Approach 2:
The treatment is applied in a controlled manner that achieves sufficient surface modification for improved bonding without over-treating the fibers. By controlling treatment parameters (power, duration, atmosphere composition), the process achieves the minimum necessary surface modification to enhance adhesion while avoiding excessive treatment that would degrade fiber strength.
2Strength
If plasma or corona treatment is applied to enhance bonding with polymeric binder materials, then fiber-binder bond strength is improved, but ballistic resistance is reduced
Solution Approach 1:
The treatment creates a differentiated structure where the fiber surface has enhanced chemical reactivity and surface energy for improved binder adhesion, while the bulk fiber maintains its original high-strength properties. This local modification ensures that bonding improvement occurs at the interface without compromising the load-bearing capacity of the fiber itself during ballistic events.
3Reliability
If plasma or corona treatment is applied to improve surface adhesion, then coating delamination is reduced, but fiber tenacity is reduced
Solution Approach 1:
The patent implements surface-selective modification where only the outer layer of the fiber is treated with plasma or corona discharge. This creates a surface with enhanced wettability, polarity, and chemical reactivity that improves coating adhesion and prevents delamination, while the internal fiber structure that determines tenacity remains unchanged and intact.
Solution Approach 2:
The treatment parameters are carefully controlled to achieve just enough surface modification to eliminate delamination issues without pushing the treatment intensity high enough to cause measurable tenacity loss. The process stops at the point where surface properties are sufficient for bonding without further treatment that would harm fiber strength.
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 process results in high tenacity fibers with enhanced bonding capabilities and reduced backface signature, maintaining or improving the fibers' physical strength and ballistic performance, allowing for superior energy dissipation during projectile impacts.
Implementation Method 1
the ability of a fiber to bond with or adhere with surface coatings may be improved by corona treating or plasma treating the fibers
Implementation Method 2
These treatments modify the fibers, such as by ablating the fiber surface, pitting or roughening of the fiber surface
Implementation Method 3
introducing polar functional groups by way of partially oxidizing the surface of the fiber
Implementation Method 4
crosslinking polymer chains near the fiber surface through free radical bonding
Implementation Method 5
corona treatment is a process in which a fiber is passed through a corona discharge station, thereby passing the fiber web through a series of high voltage electric discharges
Implementation Method 6
high voltage electric discharges, which tend to act on the surface of the fiber web in a variety of ways, including pitting, roughing and introducing polar functional groups
Implementation Method 7
wherein said surfaces are at least partially covered by a fiber surface finish; removing at least a portion of the fiber surface finish from the fiber surfaces
Data Source
AI summary
Methods for modifying high tenacity fibers without reducing the physical strength properties of the fibers. More particularly, methods for modifying fibers with a plasma treatment or a corona treatment without reducing the physical strength properties of the fibers.