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At present, developed countries mainly focus on three aspects in the research of textile technology: First, the research and development and application of new materials, and second, the use of new technologies to achieve redevelopment (new functions) and re-use (new uses) of old materials; New ideas for recreating new values ​​of old materials. Their research model includes: multi/interdisciplinary research is the core, multi/interdisciplinary technology interoperability is the main approach, and multi/interdisciplinary research and development is the major trend.
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American Smart Textile Program
At the technical research level, the United States has obvious advantages in the fields of high-performance fiber and composite materials such as carbon fiber and aramid, bio-based fiber materials, and industrial textiles such as carpets and non-woven fabrics. They attach particular importance to information technology and management information systems.
At the strategic level, national organizations, universities, and large corporations are major players in industrial core supply and industrialization. The National Strategy will promote technology integration. In April 2016, the White House established the eighth NNMI project (National Manufacturing Innovation Network Program): the Revolutionary Fiber and Textile Innovation Manufacturing Center, which aims to upgrade traditional textiles under the guidance of the NNMI project framework. Brand-new integrated and networked next-generation textiles. The Advanced Functional Fabrics of America (AFFOA) became the winning bidder, led by the Massachusetts Institute of Technology and cooperating with the U.S. Department of Defense, with 52 companies and non-profit organizations, 32 universities, and 5 state and local government departments. Representatives from 28 states participated in its operations, including major companies such as DuPont, Corning, and Intel, as well as top universities such as Cornell. Textile clearly has the most profound military colors, as well as profound materials, electronics, and Internet backgrounds.
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Germany's future textile project
The German textile industry is a model for industrial 4.0 to promote the upgrading of traditional industries. Its current three major goals are: to increase resource utilization and promote circular economy; to build a customer-centric flexible value chain, emphasizing digital manufacturing process, mass customization, and new The business model, etc.; research and development of new textile fiber materials in the future, strengthening the dominant position of German textile fiber materials.
The technological innovation system of the German textile industry is complete. There are more than 10 universities and research institutions related to textiles, and more than 2,000 R&D personnel. Universities and research institutions are committed to cross-disciplinary and cross-professional forward-looking research and development of new areas, such as "blue sky" (fundamental) research; government-funded projects are the mainstay. With the "Four University Associations" - Helmholtz Association (HGF), Max Planck Society (MPG), Fraunhofer Institute for Applied Research Promotion (FhG), Leibniz Science Association (WGL) The national research institutes represented by the Institute are related to the sub-field research institutes, and their research focuses on new fiber materials. Three world-famous professional textile research institutions (Hernnstein Institute, Duncan Dorf Institute for National Textile Fiber, Thuringian Institute of Textile Plastics (TITK)), focusing on forward-looking application research, close cooperation with companies and industries Ability.
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Japanese Textile Technology Research Direction
Japan’s high-tech fiber and high-end textile and apparel technology have obvious leading advantages. Its high-performance fiber is almost the world’s current level. It has three major high-performance fibers: carbon fiber, para-aramid, and ultra-high-molecular-weight polyethylene. The core technology; there are research and development technologies for important varieties such as polyarylate, PBO, and ultra high-strength vinylon, and its equipment manufacturing, information, and automation technologies also provide strong support for the textile industry.
Large Japanese companies are the mainstay of industrial technology supply and industrialization. For example, large enterprises such as Toray and Teijin basically have a complete technological innovation chain from fibers to textiles in addition to equipment in the field of new synthetic fibers. Toray company has production and research and development from carbon fiber to composite products. Enterprises have established R&D centers and research institutes of different nature. For example, Dongli and Teijin have set up research institutes overseas to conduct basic research on applications. Japan’s universities will provide specialized technical services for companies and jointly conduct project research and development and technical consulting services.
From these developed countries, the development of new fiber materials can be summarized into seven key words:
The first is the industrial chain and production, education and research. Even if carbon fiber is well-made, there is no composite material, and there is no doubt that no component is not.
The second is big companies and big companies. Now China is a bit of an exception. Although there are also large companies involved in this area, but overall the enthusiasm of large companies is not high.
The third is national strategy and forward-looking research.
The fourth is interdisciplinary and cross-domain. New fiber materials are not only used in the traditional textile and home textile industries, but have also spanned the entire national economy.
Fifth, big data, smart manufacturing.
Sixth, the background of the military, military transfers to civilians, and people transfer troops.
Seven is a new function, new application.
China's new fiber material industry technology and core competitiveness
Development status of new fiber materials in China
In the “13th Five-Year Development Guidance Opinions for Chemical Fibre Industry†released jointly by the Ministry of Industry and Information Technology and the National Development and Reform Commission at the end of 2016, the status quo of China’s “fiber material†industry development is targeted from three aspects: First, the overall textile industry. In 2016, China’s major pillar industries with improved competitiveness were 49.43 million tons of chemical fiber, accounting for 70% of the world’s total chemical fiber, and chemical fiber accounted for 84% of China’s textile fiber processing volume. There is no doubt that it is a pillar industry. The second is an industry with an international competitive advantage. Third, as an important part of strategic emerging industries, chemical fiber is no longer used only in traditional textiles and clothing. It is actually related to defense, military industry, transportation, energy, and health care.
Measuring the development level of a country's fiber materials generally focuses on the following aspects: First, the development of a large number of basic raw materials, namely, functional textile new materials; second, the development of bio-based chemical fiber and raw material core technologies; The breakthrough of performance fiber industrialization technology; the fourth is the cutting-edge technology research of fiber materials.
1. Significant overall technical progress in functional textile new materials
At present, China's functional fiber materials have reached the international advanced level. It is no exaggeration to take the lead in the world. The most important feature is the versatility and high performance of conventional fibers. With flame retardant, antibacterial, antistatic and other functions, such as silicon-nitrogen flame retardant viscose staple fiber, polyacrylonitrile preoxidized fiber, flame retardant polyester, flame retardant nylon, conductive polyester-acrylic composite fiber, conductive meta aramid Fiber, copper carbon nano polyamide 6 ecological antibacterial fiber, polylactic acid ecological antibacterial fiber, super fine denier porous polyester ecological antibacterial fiber, shaped polyamide 6 ecological antibacterial fiber, etc., is mainly used in special military uniforms and fire service , aircraft and high-speed rail interior materials, high-grade textiles, medical Eisai and other fields.
2. New advances in bio-based chemical fiber and raw material core technologies
Major breakthroughs have been made in key technologies: Key technologies for bio-fermentation, separation and purification of bio-based fiber raw materials, breakthrough in the production of high-deacetylation chitosan, alginate, and bamboo and pulp pulp, and green production technologies; Major breakthroughs have been made in key original technologies for the industrialization of spinning and finishing industries such as polysaccharide fibers, new solvent-based cellulose fibers, alginate fibers, and bio-based polyamide fibers.
Initially formed an industrial scale: The total capacity of bio-based chemical fiber reached 350,000 tons/year, including 195,500 tons of bio-based recycled fibers, 150,000 tons of bio-based synthetic fibers, and 0.35 million tons of marine bio-based fibers.
The preliminary establishment of the standard system has achieved a qualitative breakthrough in the construction of a bio-based chemical fiber standard system. By 2017, a total of 21 implementation standards have been issued, including 13 industry standards and 8 group standards for chemical fiber associations.
The application field has been further broadened: from the fields of clothing, home textiles and sanitary materials, to areas such as aerospace, military, transportation, industrial and medical dressings.
3. Key strategic fiber new materials
At present, all varieties of China's high-performance fiber, including carbon fiber, have been steadily developing, with a full range of products and the scale of production capacity has ranked first in the world. Carbon fiber, meta-aramid, ultra-high molecular weight polyethylene fiber, polyphenylene sulfide fiber, and continuous basalt fiber development foundation strengthening; meta-aramid, continuous basalt fiber, polyimide fiber industry development process is accelerated; polyaryletherketone The research and development of fiber and silicon carbide fibers has increased. The production technology of carbon fiber, polyimide fiber, high-performance polyethylene fiber, high-modulus aramid fiber, and polytetrafluoroethylene fiber has made remarkable progress; high-level R&D systems such as carbon fiber, aramid fiber, and basalt fiber have taken shape.
Domestically produced high-performance fibers have gradually begun to meet the needs of the defense industry. They have also been widely used in such fields as civil aviation, transportation and energy, construction machinery equipment, building structures and ocean engineering. On the whole, we have gaps with foreign countries in some aspects of bio-based fiber and high-performance fiber, but the overall level has basically reached an advanced level.
4. Frontier fiber new material
China's frontier fiber new material varieties are gradually expanding. Currently, intelligent bionic fibers represented by phase change energy storage viscose fiber, photochromic regenerated cellulose fiber, heat-retained polyacrylonitrile functional warm fiber, and artificial hollow fiber for human organs are represented. Gradually started; electrospinning nanofibers, nano-modified polyphenylene sulfide fibers, bio-nanofibers, and carbon nanotubes have made breakthroughs in theoretical research and application, with graphene-modified polyester fibers, graphene regenerated cellulose fibers. Graphene materials represented by graphene-modified polyamide 6 fiber materials have been expanding in the field of fiber applications.
In general, China has become the country with the highest coverage of high-tech fiber (including bio-based chemical fiber) production varieties; high-performance fiber production capacity and potential consumption are the first in the world; and some high-tech fiber production and application technologies have reached the international advanced level. Partially meets the needs of the defense industry and aerospace (the description during the “Twelfth Five-Year Plan†period can meet the urgent needs of the defense industry and aviation and aerospace); the multifunctionality, high performance, and low cost of conventional fibers are among the leading countries. This is an achievement. Of course, there are problems, which can be summarized as several points: lack or lack of high-level R&D institutions; market application and development cannot keep pace; technical barriers, such as new materials for aircraft, aerospace and fiber, are available abroad. Alliances or institutions similar to the official ones have to certify each component. It has been difficult for China to develop new aircraft and carbon fiber and other new materials in recent years. This is also a problem encountered in our development.
Innovation and Development of New Fiber Materials Industry in China
At present, the innovative development of China's new fiber material industry is mainly reflected in three aspects: the development and quality improvement of functional fiber materials, the industrialization of bio-based chemical fibers, the industrialization of high-performance fibers and the development of product serialization. In the future, China's new fiber materials industry will still need breakthroughs, smart manufacturing, and “3+1†major technologies (new solvent method cellulose fiber, bio-based synthetic fiber, high-performance fiber high-end production and application, and nylon melt direct spinning technology). Green manufacturing, branding, and quality improvement continue to work hard.
1. Functional fiber material development and quality improvement
(1) Development of large-capacity polymer spinning equipment
Develop high-efficiency and energy-saving large-capacity polyester polymerization and melt direct spinning equipment and process technology, break through the nylon ring air blowing technology, improve the level of high-capacity nylon equipment, and further reduce the production costs of conventional fibers. Using modular technology to achieve differentiated, functional fiber production.
(2) Development of new fiber varieties
Develop a new generation of technologies such as copolymerization, blending, multi-component, and multi-component on-line addition to realize the scaled production of differentiated fibers such as deep dyeing, ultra-fine denier, anti-pilling, and antistatic. The development of new types of hollow fiber membranes and the preparation and application of functional fibers such as flame-retardant, anti-droplet, anti-ultraviolet, anti-chemical, anti-bacterial, etc., will further increase the application ratio of chemical fiber products in industrial and home textiles.
(3) Flexible Manufacturing Technology
We will build a chemical fiber efficient and flexible manufacturing technology innovation platform, improve the engineering technology and product development capabilities, enhance the independent innovation level of key core technologies, and systematically solve the technical bottlenecks of industrial development.
2. Bio-based chemical fiber industrialization
To achieve industrialized production of bio-based chemical fibers, it is necessary to break through the manufacturing of bio-based chemical fiber key equipment; to overcome the technological bottlenecks of bio-based chemical fiber and raw material industrialization, and to realize bio-based chemical fiber production in large scale; to expand in clothing, home textiles and industry With textiles and other applications.
Bio-based recycled fibers need to break through the technological bottlenecks of the key equipment manufacturing of solvent-based cellulose fiber (Lyocell) and independent innovation technologies such as high-efficiency and low-energy solvent recovery to realize large-scale production; broaden the sources of raw materials and build demonstration production lines.
Bio-based synthetic fibers need to break through the industrialized preparation technology of bio-based synthetic fiber raw materials, focus on the development of non-food resources, bio-based fiber raw material production, and increase the polymerization and spinning of polylactic acid, polytrimethylene terephthalate and bio-based polyamides. And dyeing and finishing industrialization technology level.
Marine bio-based fibers should develop domestic marine-based raw materials such as shrimp (crab) shells and seaweed, establish a raw material base for seaweed fibers, further increase single-line production capacity, reduce production costs, and expand application fields.
3. High-performance fiber industrialization and serialization
High-performance fiber industrialization and serialized production also need to further improve and break key production and application technologies of high-performance fiber key varieties, further improve the stability of fiber performance indicators, and expand its aerospace equipment, marine engineering, advanced rail transportation, New energy automotive and power applications.
This requires high-performance fiber to achieve stable, low-cost production, focusing on expanding single-line production capacity, optimizing the control process, and achieving T300 and T700 carbon fiber, aramid 1313, ultra-high molecular weight polyethylene fiber, polyphenylene sulfide fiber, Continuous basalt fiber and other high-performance fibers are mass-produced and low-cost production. The formulation and implementation of product quality standards are strengthened, the stability of product quality is comprehensively improved, and the market competitiveness of products is further enhanced.
High-performance fibers need to be serialized, and they cannot be packaged in one or two specifications. To cooperate with production, research, and industrial chain, it is necessary to upgrade the series of high-performance fibers such as carbon fibers, aramid fibers, polyimide fibers, and PTFE fibers. To meet the needs of downstream users; breakthrough key technologies for the preparation and industrialization of new high-performance fibers such as high-strength and high-model carbon fibers, continuous silicon carbide fibers, silicon boron nitride fibers, and polyaryletherketone fibers.
At the same time, we must strengthen the construction of high-performance fiber innovation system. Learn from abroad, Europe and the United States, strengthen the development of high-performance fiber and composite materials research and application of public service platform, provide technical support for the industry and cultivate high-quality technical personnel.
In addition, we must continue to focus on smart manufacturing and big data, and improve information technology applications. From the spring survey organized by the China National Textile and Apparel Federation this year, we have found that intelligent manufacturing has developed rapidly in our industry, and it has been very successful, showing different characteristics in different aspects of the industry chain. For example, in the cotton spinning, its main direction is night shift unattended; in the printing and dyeing is automatic color separation, color matching, to achieve continuous production; smart manufacturing in the clothing reflects more of a personalized customization; in the chemical fiber is in the automatic falling tube , Automatic packaging to a three-dimensional warehouse, can save more than 50% of the staff, the production line investment payback period does not exceed 5 years, but also the unexpected harvest, with this smart warehouse, make small batches of products and sales more convenient, always The products produced in the past can be transferred out of the warehouse; after people and products have less contact, the quality of the products is generally stable; we use face recognition technology to detect the appearance of fibers, and constantly allow the machine to learn, the accuracy rate from one The initial 95% has reached 99%, and the company now envisages the collection of process data at various points in the production process, and will later achieve large-scale customization in the chemical fiber industry. This requires improving the “processing power†of the data and “value-adding†the data through “processingâ€. This involves big data, which is a collection of data that cannot be captured, managed, and processed using conventional software tools within a certain time frame. It is a massive, high growth rate, and diversified information assets that require new processing models to have stronger decision-making power, insights, and process optimization capabilities. Through continuous innovation in the industry, big data will gradually create more value.
In conclusion, chemical fiber intelligent manufacturing, represented by digital fiber full process production technology, industrial chain intelligent production traceability system, chemical fiber production intelligent logistics system, intelligent demonstration factory, and intelligent workshop breakthrough project, is the fruit of innovation in the chemical fiber new material industry. Big data and smart manufacturing may bring disruptive changes to the industry. This means that someone is going to be out of the game. Some people may come out here and there may be competition between people and machines. In any case, science and technology are our future. The development of science and technology is irreversible. We can only apply science and technology and pursue science and technology. Our chemical fiber new material industry can usher in a better tomorrow.
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