Thermoplastic Polyurethane Thread Coextrusion
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Solution Overview
Problem
Conventional threads used in industrial and footwear fabrics, such as polyester and nylon, are inadequate in durability, wear resistance, and mechanical strength, and the use of thermoplastic polyurethane threads is hindered by high processing costs and viscosity issues, leading to stiffness and productivity problems.
Innovation Solution
A method involving the coextrusion of thermoplastic polyurethane with a thickening agent like silica or talc and a lubricating agent to create a compound that is then processed into a thermoplastic polyurethane thread with enhanced properties, allowing for the production of multi-layered threads with improved tactile feel and mechanical strengths, suitable for applications like footwear and sports goods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spinning methods are used to manufacture thermoplastic polyurethane threads, then the threads can be produced, but the processing cost becomes high and the threads exhibit poor wear resistance and durability
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from spinning to coextrusion process. This parameter change enables the production of thermoplastic polyurethane threads with superior wear resistance and durability while simultaneously reducing processing costs, as coextrusion is a more cost-effective method compared to conventional spinning techniques
Solution Approach 2:
The patent employs composite materials by coextruding thermoplastic polyurethane with other polymers to create multi-layered thread structures. This composite approach enhances the wear resistance and durability of the final thread product while maintaining cost-effectiveness through the coextrusion process
2Ease of operation
If thermoplastic polyurethane resin is used to manufacture threads, then softer fabrics with improved tactility can be achieved, but the high viscosity of the resin causes manufacturing difficulties
Solution Approach 1:
The patent introduces a lubricant as an intermediary substance during the coextrusion process. This lubricant mediates between the high-viscosity thermoplastic polyurethane resin and the extrusion equipment, reducing friction and manufacturing difficulties while preserving the resin's ability to produce soft, tactile fabrics
Solution Approach 2:
The patent modifies the processing parameters by using coextrusion instead of spinning, and adjusts formulation parameters by adding lubricants to the resin compound. These parameter changes reduce the manufacturing difficulty associated with high viscosity while maintaining the tactile benefits of thermoplastic polyurethane fabrics
3Reliability
If coated threads are used to improve fabric properties, then adhesive properties can be enhanced, but the durability and wear resistance deteriorate
Solution Approach 1:
The patent creates composite multi-layered threads through coextrusion, where different polymer layers provide different functions. This composite structure inherently provides both durability from the thermoplastic polyurethane core and adhesive properties from the outer layers, eliminating the need for separate coating processes that compromise durability
Solution Approach 2:
The patent merges the adhesive function and structural function into a single coextruded thread structure. Instead of applying adhesive coatings separately (which reduces durability), the adhesive layers are integrated during the coextrusion process, maintaining both durability and adhesive properties simultaneously
4Ease of operation
If threads with fineness of 1,000 denier or greater are manufactured, then coating processes can be applied, but the threads exhibit high stiffness and are unsuitable for footwear fabrics
Solution Approach 1:
The patent changes the manufacturing process from coating to coextrusion, and utilizes the multi-layered structure to achieve flexible, fine-denier threads suitable for footwear applications
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 thermoplastic polyurethane threads with superior durability, wear resistance, and mechanical strengths, overcoming the limitations of conventional threads, and enabling their use in a wider range of applications with enhanced tactile feel and productivity.
Implementation Method 1
mixing a thermoplastic polyurethane resin and various additives together, compounding the resulting mixture
Implementation Method 2
coextruding the resulting compound with an extruder
Implementation Method 3
coextruding the resulting compound with an extruder
Data Source
AI summary
The present invention relates to a composition and a method for manufacturing a thermoplastic polyurethane thread of particularly 250 denier or less with enhanced physical properties by collecting virgin type thermoplastic polyurethane resin or polyurethane scraps remaining after using the thermoplastic polyurethane resin for airbag patterns or after processing the thermoplastic polyurethane resin, mixing various additives and the different types of thermoplastic polyurethane together, compounding the resulting mixture and then coextruding the resulting thermoplastic polyurethane compound with an extruder into a thermoplastic polyurethane thread.