Thermoplastic Elastomer Yarn Manufacturing for Shrinkage Control
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Solution Overview
Problem
Existing methods for manufacturing thermoplastic elastomer yarns fail to simultaneously improve unwinding, weaving, and yarn shrinking properties, which are crucial for producing high-quality shoe materials with desirable characteristics like air permeability, lightness, flexibility, and fashionability.
Innovation Solution
A manufacturing method involving spinning a mono filament yarn of thermoplastic elastomer material, followed by drawing, hot-air drying at 170° C. to 190° C., and oil treatment with mineral or silicon oil to achieve improved unwinding, weaving, and yarn shrinking properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional thermoplastic copolymer material is used for mono filament yarn, then the material provides good elasticity, flexibility and soft feeling, but the yarn exhibits excessive shrinkage during manufacturing process resulting in product deformation
Solution Approach 1:
The patent applies parameter changes by controlling the heat processing temperature within a specific range of 170-190°C during hot-air drying. This temperature parameter optimization prevents excessive yarn shrinkage while maintaining the elastic and flexible properties of the thermoplastic elastomer material, thereby resolving the contradiction between material softness and shrinkage control.
Solution Approach 2:
The patent implements preliminary action through pre-treatment steps including hot-air drying and oil treatment before the yarn is used in manufacturing. The oil treatment specifically prepares the yarn surface to reduce friction and prevent deformation during subsequent weaving and shoe manufacturing processes, addressing the shrinkage control issue before it affects product dimensions.
2Ease of manufacture
If hot-melt adhesive method is used for no sew manufacturing, then labor cost is reduced, but materials undergo heat and pressure causing shrinkage and product deformation
Solution Approach 1:
The patent optimizes the thermal parameters by limiting the heat processing temperature to 170-190°C during hot-air drying. This controlled temperature range allows the yarn to withstand the heat and pressure of hot-melt adhesive bonding without excessive shrinkage, enabling the no-sew manufacturing method to maintain both simplicity and dimensional accuracy.
3Strength
If yarn is drawn and hot-air dried at high temperature, then yarn strength and dimensional stability are improved, but yarn may become brittle or lose flexibility
Solution Approach 1:
The patent precisely controls the heat processing temperature within 170-190°C and implements oil treatment to maintain the balance between strength and flexibility. The oil treatment penetrates the yarn structure to plasticize the thermoplastic elastomer, preventing brittleness while preserving the strength gains from hot-air drying.
Solution Approach 2:
The patent creates a composite structure by combining the thermoplastic elastomer yarn with oil treatment agents. This composite approach enhances the yarn's mechanical properties by integrating the strengthening effect of controlled heat treatment with the flexibility-preserving effect of oil impregnation.
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 method results in a thermoplastic elastomer yarn with enhanced unwinding, weaving, and yarn shrinking properties, ensuring excellent physical properties suitable for shoe manufacturing, including reduced shrinkage, improved tensile strength, and elongation rate.
Implementation Method 1
hot-air drying the drawn yarn under a heat-processing temperature of 170° C. ̃190° C.
Implementation Method 2
processing the hot air-dried yarn with oil (oil-treating the air-dried yarn)
Data Source
AI summary
The present invention relates to a thermoplastic elastomer yarn with improved unwinding, weaving and yarn shrinking property, and a manufacturing method thereof. According to the present invention, the thermoplastic elastomer yarn according to the present invention is excellent in improved unwinding, weaving and yarn shrinking property.Furthermore, the thermoplastic elastomer yarn according to the present invention is excellent in yarn shrinkage rate, unwinding, weaving, tensile strength and elongation rate to be adequate for manufacturing textile fabric and footwear in terms of physical properties.