Polymer Yarns Research Articles

Conductive Graphene–Polyethylene Terephthalate Composite Yarns with Synergistic Multiwalled Carbon Nanotube Additives by Melt‐Spinning

Conductive graphene yarns are pivotal for embedding electronic and intelligent capabilities into fabrics. The study presents successful fabrication of conductive graphene–polyethylene terephthalate (PET) composite yarns with synergistic multiwalled carbon nanotube (MWCNT) additives through the melt‐spinning process, a widely used industrial method for polymer yarn manufacturing. The integration of MWCNTs significantly improves yarns’ electrical conductivity, achieving nearly a 100‐fold increase compared to MWCNT–PET composite yarns. The electrical performance of these yarns is primarily determined by interfacial contacts between conducting nanomaterials, which can be conceptualized as quantum tunneling barriers with multiple molecular energy levels at their extremities. Employing the Simmons model, the current–voltage characteristics is analyzed through a segmented fitting approach to extract critical barrier parameters. The equivalent barrier height and width remain constant across variations in applied voltage, nanomaterial concentration, and temperature. However, the effective total contact area increases significantly with higher nanomaterial contents, thereby substantially boosting the yarns’ electrical conductivity. The larger graphene size (≈200 nm) in comparison with the MWCNT diameter (≈5 nm) results in a substantially greater interfacial area at graphene–MWCNT contacts compared to MWCNT–MWCNT contacts. This disparity in contact area is the primary factor contributing to synergistic enhancement of electrical conductivity in graphene–PET composite yarns.

Polymeric Fibers with High Strength and High Toughness at Extreme Temperatures.

Developing strong and simultaneously tough polymeric materials with excellent thermal stability and mechanical performance even under extreme temperatures is truly a challenge. In a disruptive progress, continuous polymeric yarns are developed with a combination of high tensile strength of (1145 ± 44) MPa and ultrahigh toughness of (350 ± 24) J g-1 and high thermomechanical properties from -196 to 200°C. The comprehensive thermomechanical performance of this yarn surpasses that of previously developed polymeric materials and dragline spider silks. The results demonstrate that the molecular structure of polyimide (PI) with the incorporation of flexible-rigid macromolecular, hierarchically spiral-oriented fibers, and high glass transition temperature (248°C) are keys for the yarn's notable comprehensive performance in thermomechanical properties. The materials are ideal for technical components exposed to high thermomechanical loadings, such as those encountered in spacecraft or automotive engineering for safety-critical applications.

Influence of Yarn and Fabric Properties on Mechanical Behavior of Polymer Materials and Its Retention over Time.

The mechanical properties of textile materials play a crucial role in determining their comfort, functionality, performance, safety, and aesthetics. Understanding and optimizing these properties is essential to meet consumer demands. Key aspects of mechanical properties, such as surface roughness, abrasion resistance, and compression, have a significant impact on the touch and durability of the material, as demonstrated by various research studies. This study focuses on analyzing the mechanical properties of materials produced of different polymer yarns and their changes under combined aging factors. The findings emphasize the significance of textile abrasion resistance and surface roughness measurement, particularly for aged materials. Although the use of recycled polyester yarn is sustainable and offers advantages such as higher tensile strength, the results have shown that the use of conventional polyester yarn is more advantageous overall as it has higher abrasion resistance, a smoother surface texture, and better elasticity retention after aging. The insights presented are vital for designing high-performance sportswear, which is crucial in today's competitive environment.

Artificial Muscles Based on Coiled Conductive Polymer Yarns

AbstractLightweight artificial muscles with large strain and large stress output have great application prospects in robotics, rehabilitation, prosthetic, and exoskeletons. Despite the excellent performance of carbon nanotube‐based artificial muscles in recent years, their widespread use is hindered by the high manufacturing costs associated with carbon nanotubes. In this paper, the study introduces a novel approach by developing artificial muscles based on pure conductive polymer coiled yarns. This achievement is facilitated by the successful fabrication of high‐strength conductive polymer microfibers. Furthermore, the study elucidates the molecular structural changes occurring during electrochemical processes that induce a substantial radial volume expansion in the microfibers. The resultant anisotropic volume change is magnified by the coiled yarn, yielding a remarkable contractile strain exceeding 11% at a high stress of 5 MPa, equivalent to lifting loads more than 4000 times their own masses, all achieved with a low input voltage of 1 V. Additionally, these conductive polymer‐based artificial muscles exhibit hydration‐induced contraction up to 33%, with swift recovery through electrical heating, leveraging their intrinsic high conductivity. This breakthrough positions high‐performance conductive polymer microfibers as a promising cost‐effective alternative to carbon nanotubes, establishing them at the forefront of lightweight artificial muscles.

Impact of Fiber Characteristics on the Interfacial Interaction of Mammalian Cells and Bacteria

An imperative requisite of tissue-engineered scaffolds is to promote host cell regeneration and concomitantly thwart microbial growth. Antibacterial agents are often added to prevent implant-related infections, which, however, aggravates the risk of bacterial resistance. For the first time, we report a fiber-based platform that selectively promotes the growth of mammalian cells and alleviates bacteria by varying fiber size, orientation, and material of polymeric yarns. The interactions of Gram-positive and -negative bacterial species with mammalian mesenchymal stem cells (MSC) were investigated on poly-€-caprolactone (PCL) yarns, polyethylene terephthalate (PET), poly-L-lactic acid (PLLA), and cotton. Various yarn configurations were studied by altering the fiber diameter (from nano- to microscale) and fiber orientations (aligned, twisted, and random) of PCL yarns. PCL nanofibrous yarn decreased the adhesion of S. aureus and E. coli, with a 2.7-fold and 1.5-fold reduction, respectively, compared to PCL microfibrous yarn. Among different fiber orientations, nanoaligned fibers resulted in an 8-fold and 30-fold reduction of S. aureus and E. coli adhesion compared to random fibers. Moreover, aligned orientation was superior in retarding the S. aureus adhesion by 14-fold compared to nanotwisted fibers. Our data demonstrate that polymeric yarns comprising fibers with nanoscale features and aligned orientation promote mammalian cell adhesion and spreading and concomitantly mitigate bacterial interaction. Moreover, we unveil the wicking of cells through polymeric yarns, facilitating early cell adhesion in fibrous scaffolds. Overall, this study provides insight to engineer scaffolds that couple superior interaction of mammalian cells with high-strength fibrous yarns for regenerative applications devoid of antibacterial agents or other surface modification strategies.

Coiled Polymer Artificial Muscles Having Dual-Mode Actuation with Large Stress Generation

Coiled polymer artificial muscles with both large tensile stroke and giant force generation are needed for practical applications in robotics, soft exosuits, and prosthesis. However, most polymer yarn artificial muscles cannot generate a large force or stress. Here, we report an inexpensive Twisted and Coiled Polymer artificial muscle (TCP) that performs both large isobaric and isometric contractions. This TCP can generate a tensile stroke of 20.1% and a specific work capacity of up to 1.3 kJ kg−1 during temperature changes from 20 to 180 °C. Moreover, the nylon yarn artificial muscle produced a reversible output stress of 28.4 MPa, which is 100 times larger than human skeletal muscle. A robot arm and a simple gripper were made to demonstrate the isobaric actuation and isometric actuation of our TCP muscle, repectivley. Thus, the polymer artificial muscles with dual-mode actuation show potential applications in the field of robotics, grippers, and exoskeletons and so on.

Influence of Spinning Method on Shape Memory Effect of Thermoplastic Polyurethane Yarns.

Shape memory polymers are gaining increasing attention, especially in the medical field, due to their ability to recover high deformations, low activation temperatures, and relatively high actuation stress. Furthermore, shape memory polymers can be applied as fiber-based solutions for the development of smart devices used in many fields, e.g., industry 4.0, medicine, and skill learning. These kind of applications require sensors, actors, and conductive structures. Textile structures address these applications by meeting requirements such as being flexible, adaptable, and wearable. In this work, the influence of spinning methods and parameters on the effect of shape memory polymer yarns was investigated, comparing melt and wet spinning. It is shown that the spinning method can significantly influence the strain fixation and generated stress during the activation of the shape memory effect. Furthermore, for wet spinning, the draw ratio could affect the stress conversion, influencing its efficiency. Therefore, the selection of the spinning process is essential for the setting of application-specific shape-changing properties.

Influence of extrusion parameters on filled polyphenylsulfone tufting yarns on open-hole tensile strength

Tufting has been shown to improve the mechanical properties of composites. Unlike other published works which rely on commercially available materials, for this study, continuous polymer yarns with diameters ranging from 160 μm to 720 μm of unfilled PPSU and PPSU nanocomposites with 1 wt.% of carbon nanotubes (CNT) were prepared using a twin-screw extruder. The tensile properties of these yarns generally improved with the addition of CNT at higher values of ‘screw speed to haul-off’ ratio. This effect is correlated with the yarn draw down ratio and attributed to the nanofiller orientation induced in the thermoplastic matrix. The fibres exhibited as much as a 23% increase in Ultimate Tensile Strength (UTS) for the same parameter set when loaded with CNT. Depending on filler and processing parameters set, yarns varied in UTS from 96.4 MPa to 206.2 MPa for unfilled PPSU and PPSU-CNT, respectively.

Twisted and coiled yarns for energy harvesting and storage, artificial muscles, refrigeration, and sensing

This overview focuses on our teams work on using twisted yarns and highly elastic coiled yarns for artificial muscles, energy harvesting, energy storage, sensing, and refrigeration. Despite the diversity of these applications for coiled carbon nanotube and polymer yarns, similar fabrication methods are applicable and conversion of coiling twist to yarn twist results in yarn elasticity, actuation, twistocaloric cooling, and the capacitance changes used for energy harvesting and sensing. Likewise, the same biscrolling method yields coiled yarns containing up to 95 weight percent of guest powders that provide various new properties. The obtained performance of the coiled polymer and carbon nanotube yarns are remarkable, such as artificial muscles that generate up to 98 times the output mechanical power than the maximum for the same weight human muscle and mechanical energy harvesters providing a higher peak electrical power per weight than prior art material-based mechanical energy harvesters for stretch frequencies between a few Hz and 600 Hz.

Deposition of ZIF-67 and polypyrrole on current collector knitted from carbon nanotube-wrapped polymer yarns as a high-performance electrode for flexible supercapacitors

Polymeric fiber fabrics with inherent mechanical flexibility, lightweight and porous textile structure are highly attractive as an ideal substrate for building flexible electrodes. However, their insulating nature limits their direct application as current collector. Here, we designed and fabricated a flexible conductive fabric from polymer yarns. This was achieved through wrapping polymer yarns with a carbon nanotube (CNT) cylinder, which was continuously prepared from a floating catalyst chemical vapor deposition process, and a subsequent knitting process. The derived CNT-wrapped polymer yarn fabric (CPYF) could directly serve as current collector/substrate to load zeolitic imidazolate framework-67 (ZIF-67) and polypyrrole (PPy) through in-situ growth and chemical polymerization. The resultant CPYF-ZIF-67-PPy displayed a maximum areal capacitance of 2308.8 mF cm−2 at 0.5 mA cm−2. Moreover, the assembled supercapacitor achieved a maximum areal energy density of 112 μW h cm−2 at the power density of 201.5 μW cm−2. Meanwhile, the device demonstrated an extraordinary flexibility with stable electrochemical properties after 5000 cycles of bending and 1000 cycles of stretching. This work therefore offers a new strategy that can be used to develop flexible conductive fabric for flexible supercapacitors.

Development of Multifunctional Nano-Graphene-Grafted Polyester to Enhance Thermal Insulation and Performance of Modified Polyesters.

Nano-graphene materials have improved many thermal properties based on polymer systems. The additive polymers’ thermal insulation cannot be significantly increased for use as a reinforcement in multifunctional thermally insulating polymer foam. Herein, we present the development of far-infrared emissivity and antistatic properties using multifunctional nano-graphene polyester fibers. Nano-graphene far-infrared thermal insulation polyester was synthesized with 2% nano-graphene and dispersant polypropylene wax-maleic anhydride (PP wax-MA) using the Taguchi method combined with grey relational analysis (GRA) to improve the thermal properties and the performance of the polymer composite. The thermogravimetric analysis (TGA) shows that the pyrolysis temperature of spinning-grade polyester was increased when the nano-graphene powder was added to the polyester. The differential scanning calorimeter (DSC) analysis confirmed the modification of polyester by nano-graphene, showing the effect of the nucleating agent, which ultimately improved the performance of the polyester. The physical properties of the optimized polyester fibers were improved with a yarn count of 76.5 d, tensile strength of 3.3 g/d, and an elongation at break increased from 23.5% to 26.7% compared with unmodified polymer yarn. These far-infrared emission rates increased from 78% to 83%, whereas the far-infrared temperature increased from 4.0 °C to 22 °C, and the surface resistance increased to 108 Ω. The performance of the optimized modified polyester yarn is far better than single-polypropylene-grafted maleic anhydride yarn. The performance of optimized modified polyester yarn, further confirmed using grey correlation analysis (GRA), can improve the yarns’ mechanical properties and far-infrared functions. Our findings provide an alternative route for developing nano-graphene polyester fabrics suitable for the fabric industry.

Evaluation of residual strength of polymeric yarns subjected to previous impact loads

The discovery of oil fields in deep and ultra-deep waters provided an opportunity to evaluate the use of synthetic ropes, complementarily or alternatively to traditional steel-based mooring lines in offshore units, mainly because of the former’s lower specific weight. Considering the series of complex dynamic-mechanical mainly axial loads to which these structures may be subjected, originated from different sources, such as wind, water current, tide, etc., there may be cases when at least one of these lines may possibly face an abrupt, shock-like axial load of considerably larger magnitude. The goal of the present study is to evaluate the residual tensile strength of three different synthetic yarns (polyester, and two grades of high modulus polyethylene) after exposure to such axial impact loads. It was observed that, for the tested materials, polyester is the one with the largest impact resistance to the conditions evaluated herein, mainly because of its comparatively greater energy absorption properties.

Statistical approach to optimize crashworthiness of thermoplastic commingled composites

A design of experiments analysis was developed to relate the processing conditions to the impact energy absorption capability of thermoplastic commingled composites. Based on low velocity impact test responses and statistical modeling, a factorial design was implemented to investigate the interaction of processing parameters with the polymer viscosity. The influence of thermal consolidation on materials performances were evaluated and quantified. The dataset was obtained according to the impact energy capability of carbon fiber/polyamide and carbon fiber/poly (ether-ether-ketone) commingled composites. The results identified the best combination of variables which improves crashworthiness of structural composites and leads to high impact energy absorption capabilities. The results revealed that the commingled composites crashworthiness strongly depends on the polymer yarn dispersion in the carbon fiber tow, that was identified and classified in different distribution patterns. This work represents a significant step towards manufacturing of thermoplastics composites with target structural performance.

Influence of Carbon Nanotubes Concentration on Mechanical and Electrical Properties of Poly(styrene-co-acrylonitrile) Composite Yarns Electrospun.

In this work, the influence of carbon nanotubes (CNTs) content on the mechanical and electrical properties of four series of polymeric matrix were made and their cytotoxicity on cells was evaluated to consider their use as a possible artificial muscle. For that, polymer composite yarns were electrospun using polymeric solutions at 10 wt.%. of poly(styrene-co-acrylonitrile) P(S:AN) and P(S:AN-acrylic acid) P(S:AN-AA) at several monomeric concentrations, namely 0:100, 20:80, 40:60, 50:50 (wt.%:wt.%), and 1 wt.% of AA. Carbon nanotubes (CNTs) were added to the polymeric solutions at two concentrations, 0.5 and 1.0 wt.%. PMCs yarns were collected using a blade collector. Mechanical and electrical properties of polymeric yarns indicated a dependence of CNTs content into yarns. Three areas could be found in fibers: CNTs bundles zones, distributed and aligned CNTs zones, and polymer-only zones. PMCs yarns with 0.5 wt.% CNTs concentration were found with a homogenous nanotube dispersion and axial alignment in polymeric yarn, ensuring load transfer on the polymeric matrix to CNTs, increasing the elastic modulus up to 27 MPa, and a maximum electrical current of 1.8 mA due to a good polymer–nanotube interaction.

Highly stretchable durable electro-thermal conductive yarns made by deposition of carbon nanotubes

The polymer yarns are originally electrical insulators. Their structure does not provide valence electrons to conduct electrical current. The coating of carbon nanotubes (CNT) over the nylon yarn enables it to become a good conductor of heat and electricity. The objective of present study is to impart the electrical conductivity to the Nylon 6/Spandex yarn by coating the CNT. The physical properties of CNTs were studied by SEM analysis. The electrical properties of CNT coated yarns were investigated in relaxed and stretched state. The conductive yarns showed low resistance under high stretch load. Furthermore, the heating performance of the CNT coated yarns was analyzed by applying the different range of voltages at the surface of the yarns. The maximum temperature of about 280 °C was recorded when the applied voltages were 5 V for 60 min. Moreover, the durability of CNT coated yarns was observed against severe washing. The yarns showed good retention of the CNT even after severe washing, as proved by a very small loss in the electrical conductivity of the yarns.

Mathematical modeling of deformation and relaxation processes of polymer yarn

Mathematical modeling of deformation and relaxation processes of polymer yarn

Electrical stimulation of co-woven nerve conduit for peripheral neurite differentiation

Electrically stimulable nerve conduits are implants that could potentially be utilized in patients with nerve injury for restoring function and limb mobility. Such conduits need to be developed from specialized scaffolds that are both electrically conductive and allow neuronal attachment and differentiation. In this study, we investigate neural cell attachment and axonal differentiation on scaffolds co-woven with poly-(L-lactic acid) (PLLA) yarns and conducting threads. Yarns obtained from electrospun PLLA were co-woven with polypyrrole (PPy)-coated PLLA yarns or ultrathin wires of copper or platinum using a custom built low-resistance semi-automated weaving machine. The conducting threads were first electrically characterized and tested for stability in cell growth media. Suitability of the conducting threads was further assessed via cell viability studies using PC12 cells. Neurite growth was then quantified after electrically stimulating rat dorsal root ganglion (DRG) sensory neurons cultured on the woven scaffolds. Electrical conductivity tests and cellular viability studies demonstrated better bio-tolerability of platinum wires over PPy-coated PLLA yarns and copper wires. Electrically stimulated DRG neurons cultured on platinum-PLLA co-woven scaffolds showed enhanced neurite outgrowth and length. We demonstrate that a woven scaffold design could be utilized to incorporate conducting materials into cell-tolerable polymer yarns for developing electrically stimulable nerve conduits.

Experimental study on texturability of filament yarns produced from recycled PET

In the present work, the texturability of filament yarns produced from recycled bottle grade polyethylene terephthalate (R-PET) and new fiber grade PET (FG-PET) were investigated and compared experimentally. Yarn spun on a spin-draw spinning machine was draw-textured. Elongation at break in each fiber was set to reach 30 ± 5% in the texturing machine. The effect of the draw-texturing conditions on thermomechanical, structural, and crimp properties were examined. Draw-texturing behaviors of the fibers were analyzed using differential scanning calorimetry and measurements of intrinsic viscosity, mechanical and crimp properties, density, and X-ray diffraction. The results indicate that crystallinity of the textured yarn from R- PET and FG-PET has increased compared to the semi-drawn yarns. Further, the lateral dimensions of the R-PET crystals are relatively well developed. Crimp properties show nearly similar response for two polymer yarns for the texturing process. It was found that R-PET can be the premier feed supply for the draw-texturing process and that filaments with appropriate confidence could be obtained from the R-PET.

Surface modification of polymer textile biomaterials by N2 supercritical jet: Preliminary mechanical and biological performance assessment

Foreign Body Reaction (FBR) is a critical issue to be addressed when polyethylene terephthalate (PET) textile implants are considered in the medical field to treat pathologies involving hernia repair, revascularization strategies in arterial disease, and aneurysm or heart valve replacement. The natural porosity of textile materials tends to induce exaggerated tissue ingrowth which may prevent the implants from remaining flexible. One hypothesized way to limit the FBR process is to increase the material surface roughness at the yarn level. Supercritical N2 (ScN2) jet particle projection is a technique that provides enough velocity to particles in order to induce plastic deformation on the impacted surface. This work investigates the influence of ScN2 jet projection parameters like standoff distance or particle size on the roughness that can be obtained on medical polymer yarns of various diameters (100 and 400 μm) and woven textile surfaces obtained from a 100 μm yarn. Moreover, the mechanical and biological performances of the obtained modified textile material are assessed. Results bring out that with appropriate testing conditions (500 bars jet/500 mm distance between nozzle and PET textile) and particle size around 50 μm, it is possible to generate 20 μm large and 4 μm deep craters on a 100 μm monofilament PET yarn and fabric. Regarding the strength of the textile material, it is only slightly modified with the treatment process, as the tenacity of the yarns decreases by only 10%. Moreover, It is shown that the obtained structures tend to limit the adhesion and slow down the proliferation of human fibroblasts.

Influence of monomeric concentration on mechanical and electrical properties of poly(styrene‐co‐acrylonitrile) and poly(styrene‐co‐acrylonitrile/acrylic acid) yarns electrospun

AbstractTwo series of copolymers were synthesized by emulsion polymerization: poly(styrene‐co‐acrylonitrile) P(S:AN) and P(S:AN‐acrylic acid) P(S:AN‐AA). The monomeric concentrations in both series were: 0:100, 20:80, 40:60, 50:50 (wt%:wt%), and 1 wt% of AA. The copolymers were dissolved in N,N‐dimethylformamide (4–10 wt%) and were electrospun. Polymeric yarns were collected using a blade collector. The synthesized and fabricated materials were characterized by known techniques. Mechanical and electrical properties of polymeric yarns indicated a dependence of monomeric concentration. Elastic modulus increases as acrylonitrile concentration increases (up to 30 MPa). Yarns were submitted to degradation process into saline solution, where the acrylic acid content kept a constant elastic modulus at long times. The electrical current into yarns was higher when the concentration is 50:50 wt%:wt% (1.2 mA). The cytotoxicity results showed a cell viability close to 100% for yarns without AA.