TPU Coated Yarn Compound for Thin, Matte, Durable Coatings
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Solution Overview
Problem
Coated yarns made from polyester, nylon, or spandex have low durability, abrasion resistance, and mechanical strength, limiting their use in industrial applications due to low viscosity of thermoplastic polyurethane coatings and glossy surfaces requiring additional matting processes.
Innovation Solution
A thermoplastic polyurethane compound composition is developed by mixing thermoplastic polyurethane with additives such as silica, talc, or calcium carbonate as thickeners, processed in an extruder to create a coating solution with increased viscosity, allowing for higher productivity and production of coated yarns with desired thickness and color.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermoplastic polyurethane is used to coat yarn, then the coating provides basic protection, but the low viscosity of the thermoplastic polyurethane reduces productivity and makes it impossible to produce coated yarn with thin thickness
Solution Approach 1:
The patent changes the viscosity parameter of the thermoplastic polyurethane by adding specific additives (wax and/or oil) to increase it from low viscosity to a range of 10-1000 Pa·s at processing temperature. This parameter change enables both improved productivity through better coating control and achievement of thin thickness specifications while maintaining manufacturability.
Solution Approach 2:
The patent creates a composite coating material by combining thermoplastic polyurethane with wax and/or oil additives. This composite formulation achieves the desired viscosity characteristics and coating properties that neither component could achieve alone, resolving the contradiction between productivity and thickness control.
2Ease of manufacture
If thermoplastic polyurethane is used to coat yarn, then the coating provides basic protection, but the surface becomes glossy requiring additional matting processes
Solution Approach 1:
The patent changes the surface properties parameter by incorporating wax and/or oil into the coating composition. These additives modify the surface characteristics to achieve matting effect directly during the coating process, eliminating the need for separate matting operations and reducing overall process complexity.
Solution Approach 2:
The patent merges the coating application and matting functions into a single integrated process step. By incorporating matting agents (wax and/or oil) into the coating composition itself, the patent combines what would traditionally be separate operations into one unified manufacturing step, simplifying the overall process.
3Reliability
If conventional coating materials like PVC or PP are used, then productivity is maintained, but the durability, abrasion resistance, and mechanical strength are insufficient for long-term industrial use
Solution Approach 1:
The patent creates a composite coating system using thermoplastic polyurethane as the base material combined with wax and/or oil additives. This composite formulation maintains the superior durability, abrasion resistance, and mechanical strength of thermoplastic polyurethane while the additives modify rheological properties to enable efficient processing and high productivity comparable to conventional materials.
Solution Approach 2:
The patent changes the viscosity parameter of thermoplastic polyurethane through additive incorporation, transforming it from a material with processing difficulties to one that can be efficiently coated at high speeds. This parameter modification enables thermoplastic polyurethane to achieve both high reliability and high productivity simultaneously.
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 solution enhances the durability, abrasion resistance, and mechanical strength of coated yarns, enabling their use in various applications including sports goods, daily necessities, and industrial supplies, with improved productivity and matting properties.
Implementation Method 1
mixing thermoplastic polyurethane with additives such as silica, talc, or calcium carbonate as thickeners, processed in an extruder to create a coating solution with increased viscosity
Implementation Method 2
processed in an extruder to create a coating solution with increased viscosity
Data Source
AI summary
The present invention provides a method for manufacturing a coated yarn having outstanding physical properties, the method comprising: collecting thermoplastic polyurethane in virgin form, as scraps remaining after being suitably used for airbag patterns in a shoe manufacturing process, or as scraps remaining after other thermoplastic polyurethane is processed; mixing the various kinds of thermoplastic polyurethane with various additives; compounding the resultant mixture using an extruder to prepare a thermoplastic polyurethane compound for a coated yarn; and coating the surface of a yarn made from polyester, nylon, spandex, etc. with the compound using an extruder.