Enhanced Meta-aramid And Para-aramid Textiles, Garments, And Methods

Haggquist; Gregory W. ;   et al.

Patent Application Summary

U.S. patent application number 15/081466 was filed with the patent office on 2017-01-26 for enhanced meta-aramid and para-aramid textiles, garments, and methods. The applicant listed for this patent is Cocona, Inc.. Invention is credited to Wesley Wade Burgess, Gregory W. Haggquist.

Application Number20170022634 15/081466
Document ID /
Family ID56977754
Filed Date2017-01-26

United States Patent Application 20170022634
Kind Code A1
Haggquist; Gregory W. ;   et al. January 26, 2017

ENHANCED META-ARAMID AND PARA-ARAMID TEXTILES, GARMENTS, AND METHODS

Abstract

A textile comprising a plurality of synthetic fibers and a plurality of active particles. The plurality of synthetic fibers comprise a plurality of meta-aramid and/or para-aramid fibers. The plurality of active particles are physically embedded in the plurality of synthetic fibers. The plurality of active particles comprise a higher heat stability temperature than the plurality of synthetic fibers.


Inventors: Haggquist; Gregory W.; (Longmont, CO) ; Burgess; Wesley Wade; (Beech Mountain, NC)
Applicant:
Name City State Country Type

Cocona, Inc.

Boulder

CO

US
Family ID: 56977754
Appl. No.: 15/081466
Filed: March 25, 2016

Related U.S. Patent Documents

Application Number Filing Date Patent Number
62138325 Mar 25, 2015

Current U.S. Class: 1/1
Current CPC Class: D10B 2401/02 20130101; D01F 1/07 20130101; A41D 31/08 20190201; A62B 17/003 20130101; A41D 31/12 20190201; A41D 31/102 20190201; D01F 6/605 20130101; D01D 5/06 20130101; A41D 13/0512 20130101; D10B 2501/042 20130101; A41D 2500/50 20130101; D01D 5/38 20130101; D10B 2331/021 20130101
International Class: D01F 1/07 20060101 D01F001/07; A41D 13/05 20060101 A41D013/05; D01F 6/60 20060101 D01F006/60; D01D 5/06 20060101 D01D005/06; D01D 5/38 20060101 D01D005/38

Claims



1. A textile comprising, a plurality of synthetic fibers, the plurality of synthetic fibers comprising a plurality of meta-aramid and/or para-aramid fibers; a plurality of active particles physically embedded in the plurality of synthetic fibers, wherein the plurality of active particles comprise a higher heat stability temperature than the plurality of synthetic fibers.

2. The textile of claim 1 wherein, the textile comprises a first side and a second side; and the active particles decrease the humidity and/or an amount of liquid between the first side and a user's skin upon wearing the textile.

3. The textile of claim 2 wherein, the first side comprises a textile side nearest to a user's skin upon wearing the textile; and the second side comprises a textile side farther from the user's skin upon wearing the textile.

4. The textile of claim 1 wherein, the weight ratio of active particles to synthetic fibers comprises a range of about to about 0.01% to 3%; and the active particles increase a resistance to burning for the textile.

5. The textile of claim 4 wherein, the resistance to burning comprises, a non-melting textile; a non-dripping textile; and a textile comprising, less than two second of afterglow and after flame, and less than four inches of char length.

6. The textile of claim 1 wherein, the active particles, are between about 100 nm and 10 microns in diameter; absorb light comprising wavelengths from about 8 microns to about 12 microns; absorb and eject water, wherein the water comprises a temperature between about 10 degrees Celsius and about 40 degrees Celsius; and comprise a surface area greater than 10 m.sup.2 per gram of active particles.

7. The textile of claim 6 wherein, the light comprises infrared light; and an increased water evaporation rate for the textile when the active particle is present.

8. The textile of claim 6 wherein, the water evaporation rate comprises moisture entering the textile at a textile first side and leaving the textile at a textile second side; a temperature of the water at the textile first side comprises a temperature near a user's body temperature; the temperature of the water at the textile second side comprises an ambient temperature.

9. A fire-resistant garment comprising, a plurality of synthetic fibers, the plurality of synthetic fibers comprising a plurality of meta-aramid and/or para-aramid fibers; a plurality of active particles physically embedded in the plurality of synthetic fibers, wherein the plurality of active particles comprise a higher heat stability temperature than the plurality of synthetic fibers.

10. The fire-resistant garment of claim 9 further comprising, a first garment section; and a second garment section.

11. The fire-resistant garment of claim 10 wherein, one of the first garment section and the second garment section comprises a head and/or neck covering; and no skin is exposed to an ambient environment upon wearing the fire-resistant garment.

12. The fire-resistant garment of claim 9 further comprising, a plurality of natural porous fibers blended with the plurality of synthetic fibers; and one or more openings to access a first garment side from a second garment side.

13. The fire-resistant garment of claim 12 wherein, the plurality of synthetic fibers doped with active particles comprises cotton and/or polyester; and the synthetic fibers doped with active particles is no greater than 35%.

14. A method of creating a composite polymer textile comprising, creating a solution by dissolving polymers comprising meta-aramids and/or para-aramids into a solvent; dispersing active particles into the solution; spinning the solution using a spinneret; polymerizing or precipitating the solution into a meta-aramid and/or para-aramid fiber material; and physically incorporating the active particles into the meta-aramid and/or para-aramid fiber material.

15. The method of claim 14 wherein, the solvent comprises sulfuric acid.

16. The method of claim 14 wherein, the active particles are insoluble and physically unaffected by the solvent.

17. The method of claim 14 wherein, the active particles are dispersed into the solution before and/or during the spinning of the solution using a spinneret.

18. The method of claim 14 wherein the active particles are dispersed directly into the solution or: by using a dispersing agent, or through the use of a removable encapsulant.

19. The method of 18 wherein, the active particles are dispersed using a dispersing agent and further comprising, substantially decreasing the agglomeration of active particles; and substantially decreasing the number of active particles that fall out of the solution.

20. The method of claim 14, wherein, physically incorporating the active particles into the meta-aramid and/or para-aramid fiber material occurs during the spinning of the solution and comprises using dispersion forces or van der Waals forces to hold the active particles and the meta-aramid and/or para-aramid fiber material together.
Description



PRIORITY

[0001] This application claims priority to U.S. Provisional Application No. 62/138,325, filed Mar. 25, 2015 and entitled "Enhanced Meta-Aramid and Para-Aramid Fibers", which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to textile fibers. In particular, but not by way of limitation, the present disclosure relates to articles and methods for incorporating active particles into meta-aramid and para-aramid fibers for improving the physical characteristics of flame-resistant textiles.

BACKGROUND OF THE DISCLOSURE

[0003] Meta-aramid and para-aramid fibers are used in protective textiles to protect objects and/or humans from excessive heat exposure and burning caused by open flames. These fibers are adapted to self-extinguish when they are exposed to a flash fire or heat event. Various industry-standard test methods are used to determine the heat resistance, flame resistance, and self-extinguishing characteristics of such protective textiles. Examples of common tests include the methods found in ASTM D6413, ASTM F2700, and ASTM 2703, as well as the PyroMan.TM. test method, developed by Ansell Protective Solutions AB, Johan Kocksgatan 10, SE-231 81 Trelleborg, Sweden. The benefits of protection that meta-aramids and para-aramids provide allow meta-aramids and para-aramid fibers to be used in a wide range of applications where flame resistance is required.

[0004] Wearing garments comprising meta-aramid and para-aramid fibers provide the benefits of protecting the wearer from flame exposure, but these benefits come at a cost of human comfort, since moisture is unable to move through meta-aramid and para-aramid fiber material. Similarly, meta-aramid and para-aramid materials used to protect industrial components have the benefit of protecting the parts from flame exposure, but moisture build-up between the textile and the industrial component can cause other problems. The movement of water vapor or liquid water is important in either extending the comfort range for a human or to keep an industrial part at an optimum moisture level.

SUMMARY OF INVENTION

[0005] These materials have a need to have improved moisture function to extend the usage capability. It is desirable to improve on the functionality of these products against a flame and other thermal events. One embodiment of an invention providing these improvements comprises a textile comprising a plurality of synthetic fibers. In such a textile, the plurality of synthetic fibers comprise a plurality of meta-aramid and/or para-aramid fibers. A plurality of active particles are physically embedded in the plurality of synthetic fibers, with the plurality of active particles comprising a higher heat stability temperature than the plurality of synthetic fibers.

[0006] Another embodiment of the invention comprises a fire-resistant garment. One such fire-resistant garment comprises a plurality of synthetic fibers and a plurality of active particles physically embedded in the plurality of synthetic fibers. The plurality of synthetic fibers comprises a plurality of meta-aramid and/or para-aramid fibers and the plurality of active particles are physically embedded in the plurality of synthetic fibers. Furthermore, the plurality of active particles comprises a higher heat stability temperature than the plurality of synthetic fibers.

[0007] Yet another embodiment of the invention comprises a method of creating a composite polymer textile. One such method comprises creating a solution by dissolving meta-aramid and/or para-aramid polymers into a solvent and dispersing active particles into the solution. The solution is then spun using a spinneret, polymerizing or precipitating the solution into a meta-aramid and/or para-aramid fiber material and physically incorporating the active particles into the meta-aramid and/or para-aramid fiber material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various objects and advantages and a more complete understanding of the present invention are apparent and more readily appreciated by reference to the following Detailed Description and to the appended claims when taken in conjunction with the accompanying Drawings wherein:

[0009] FIG. 1 depicts a basic chemical structure of a para-aramid and a meta-aramid according to one embodiment of the invention;

[0010] FIG. 2 depicts a microscopic image of zeolite according to one embodiment of the invention;

[0011] FIG. 3 depicts a microscopic image of activated carbon according to one embodiment of the invention;

[0012] FIG. 4 depicts garments according to one embodiment of the invention;

[0013] FIG. 5 depicts a graphical representation of the moisture management properties of a section of meta-aramid and/or para-aramid textile without active particles and a section of meta-aramid and/or para-aramid textile with active particles, according to one embodiment of the invention;

[0014] FIG. 6 depicts two microscopic views of active particles as they would be physically incorporated with meta-aramid or para-aramid fibers, according to one embodiment of the invention; and

[0015] FIG. 7 depicts a method of creating a composite polymer textile according to one embodiment of the present invention.

DETAILED DESCRIPTION

[0016] The term "or" as used in this specification and the appended claims is meant to be an exclusive identification between two terms, meaning "either". Therefore, when the "or" term is used with reference to items A and B, for example, as in "items A or B", the phrase should be viewed as "either of item A and item B, not both of item A and B." The term "and" as used in the appended claims and the specification is mean to be inclusive. In using the item A and B example above, the phrase "item A and item B" should be viewed as "both of item A along with item B." If the term "and/or" is used in the claims and specification, the term should be viewed as inclusive and exclusive. Therefore, in the example above, the phrase "A and/or B" should be viewed as "either `A or B` or `A and B`".

[0017] References in the specification to "one embodiment", "an embodiment", "a preferred embodiment", "an alternative embodiment", "a variation", "one variation", and similar phrases mean that a particular feature, structure, or characteristic described in connection with at least one embodiment of the invention. The appearances of phrases like "in one embodiment", "in an embodiment", or "in a variation" and similar phrases in various places in the specification are not necessarily all meant to refer to the same embodiment or variation and may refer to multiple embodiments or variations. Similarly, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any use of the term "exemplary" herein is not necessarily to be construed as preferred or advantageous over other embodiments.

[0018] An aramid fiber comprises a manufactured fiber in which the fiber-forming substance is a long-chain synthetic polyamide where at least 85% of the amide linkages (CO--NH--) in the polyamide are attached directly to two aromatic rings. Meta-aramid and para-aramid fibers differ slightly in their chemical composition as compared to purely aramid fibers. Specifically, the position on the aromatic rings to which the meta-aramid and para-aramid fibers bond differs as compared to purely aramid fibers. FIG. 1 displays the difference in chemical structure and molecular diagrams between a para-aramid 100 and a meta-aramid 150 polymer, respectively. Meta-aramid and para-aramid fibers also differ slightly with regard to tensile, strength, and other properties.

[0019] Fibers comprising the meta-aramid 150 and para-aramid 100 structure seen in FIG. 1 comprise commercially-available textiles such as, but not limited to, the materials marketed and sold under the Kevlar.RTM. and Nomex.RTM. brands from E. I. du Pont de Nemours and Company, 1007 Market Street Wilmington Del. 19898, as well as the material marketed and sold under the Twaron.RTM. trademark from Teijin Aramid B.V. Limited Liability Company, Velperweg 76, Arnhem, Netherlands 6824 BM. These textiles, among others, are used in many environments in which individuals, such as such as military personnel, first responders, and factory workers, require specialized flame-resistant apparel. However, a main feature of these materials is also a drawback to their use. Specifically, the highly impermeable nature of these materials to fire also leads to the materials being highly impermeable to water and therefore have little to no water adsorption or absorption properties. As such, when these materials are worn, the heat causing a person to sweat creates humidity between the user and the material, making the air around the body highly uncomfortable within a very short period of time.

[0020] As stated, meta-aramid and para-aramid fibers are also useful in protecting structures and objects from heat and flame. In industrial settings, pipes, tanks, pumps, and other structures and equipment can be protected from damage with hoses or wraps comprised of meta-aramid or para-aramid fibers surrounding the equipment/structures. However, many pieces of industrial equipment or structures also create condensation during operation and this water buildup between the flame-resistant material and the equipment can introduce additional problems. Meta-aramid and para-aramid textiles are also further used in building materials as a substitute for asbestos and/or other construction materials in walls and ceilings. Building materials that include meta-aramid and para-aramid textiles can cause humidity buildup within buildings. In nearly every application of meta-aramid and para-aramid materials, in order to alleviate the effects of humidity buildup, some kind of ventilation is usually implemented. However, depending on how various methods of ventilation are implemented, the ventilation may compromise the effectiveness of the flame-resistance system.

[0021] In order to alleviate this compromised effect of ventilation, yet still provide decreased humidity in meta-aramid and para-aramid materials, an embodiment of the invention comprises a textile in which active particles are integrated into meta-aramid and para-aramid fibers. One type of textile may comprise a woven material, a non-woven material, or a performance-enhanced material. The term "active particle" may be defined as a material with a specific set of physical properties that interact with the environment to achieve particular performance characteristics. One type of active particle textile may comprise a polymer composite comprising meta-aramid and/or para-aramid fibers and one or more active particles. For ease of reference, textiles in accordance with embodiments of the present disclosure comprising active particles and either meta-aramid or para-aramid fibers may be referred to as "composite textiles" or "composite polymer textiles."

[0022] The active particles in composite textiles achieve two desired performance characteristics: First, the active particles may provide moisture management characteristics in the form of a decreased or a substantial elimination of humidity and liquid between the skin of the textile wearer and the textile; Second, the particles may enhance the flame-resistant performance (i.e., increased resistance to burning when in contact or near a direct flame) of the textile, beyond the existing characteristics if the textile contains only meta-aramid and para-aramid fibers. For example, to meet the requirements of ASTM D6413, the material must not melt or drip, have less than 2 seconds of afterglow and after flame, and less than 4 inches of char length. In order to achieve these characteristics, the active particles themselves have particular properties.

[0023] Providing desired moisture management properties to a textile may be obtained through adding to the textile active particles that 1) absorb infrared light in the 8 to 12 micron wavelength region, 2) have the ability to adsorb and desorb (i.e., eject or emit) water at temperatures between 10 and 40.degree. C., and 3) have a surface area greater than 10 m.sup.2/g. Water is absorbed by the active particles when the person begins to perspire while wearing the garment. The active particles desorb the adsorbed liquid or vapor when infrared light is absorbed by the active particle, comprising enough energy to cause the water to desorb from the particle. It is contemplated that the infrared light may be emitted by the person wearing the garment. In one embodiment, the amount of active particles in the textile may comprise from about 0.01% to about 3% by weight. However, the active particle loading level may be determined based on the strength of the fiber. In some embodiments, increased active particle loading may occur with increased tensile strength. The amount of water that is absorbed and desorbed from the active particles may comprise an evaporation rate. One or more of these particular properties may be collectively referred to throughout the disclosure as the "moisture management properties." The specific moisture management properties described herein provide certain advantages which result in the desired characteristics of the composite textile. For example, one advantage that the capturing of infrared energy in the 8 to 12 micron wavelength region provides is an increase of the evaporation rate of water as compared to its normal evaporation rate. For example, woven fabric comprising Nomex.RTM. material without active particles comprises an AATCC 200 drying rate of about 0.73 ml/h and the same Nomex.RTM. fabric material with active particles comprises a drying rate of about 3.5 ml/h. Such woven fabric may comprise of 15% polyethylene terephthalate (PET) doped with 1% active particles blended with 85% Nomex.RTM. fibers. Additionally, the ability to adsorb and desorb water while wearing the garment ensures that moisture can pass through the composite textile at body temperature and at normal ambient environmental temperatures. The surface area property of greater than 10 m.sup.2/g generally indicates that a particle has high porosity. High porosity can be advantageous in active particles of the present disclosure because the large surface area created by pores allows a relatively large amount of water to be adsorbed to the surface of a particle in comparison to its overall size, thereby creating a flow of perspiration from the wear of the garment to the ambient environment, as described above.

[0024] In order to enhance the flame-resistant characteristics of the textile, the active particles may have a heat (thermal) stability of greater than 300.degree. C. and a specific heat of less than 1.3 J/gK at 293K. Many existing meta-aramid and para-aramid fibers have a heat stability (otherwise known as a thermal degradation temperature) of between 200 and 260.degree. C. Incorporating active particles with a higher heat stability temperature than the meta-aramid and para-aramid fibers is advantageous because it is likely that the composite textile will be exposed to temperatures of at least 200 to 260.degree. C. In order to preserve the moisture management functionality of the active particles, they should not degrade (e.g., decomposition and volatilization) at temperatures that the meta-aramid and para-aramid fibers are designed to be exposed to. Further, adding the active particles as described in the present disclosure may increase the overall heat stability of the textile to a higher temperature threshold than existing meta-aramid and para-aramid fibers. Several types of active particles can be utilized in embodiments of the present disclosure, including zeolite and activated carbon. In many embodiments, active particles may be minerals that may absorb and desorb water with human infrared energy. Any type of active particle having one or more of the properties listed herein may be used without departing from the scope of the present disclosure.

[0025] FIG. 2 depicts a microscopic image, as seen through a scanning electron micrograph, of zeolite 275, an active particle that may be integrated with meta-aramid or para-aramid fibers according to aspects of the present disclosure. FIG. 3 also depicts a close view, as seen through a scanning electron micrograph, of activated carbon 325, another activated particle that may be integrated with meta-aramid or para-aramid fibers according to aspects of the present disclosure.

[0026] As seen in FIGS. 2 and 3, activated carbon 325 and zeolite 275 typically comprise a rough surface with many pores, which result in a single particle having a large surface area. As discussed previously, the large surface-area-to-size ratio allows for activated particles to adsorb relatively large amounts of a particular substance, such as water. In certain embodiments, activated carbon may be in the form of activated charcoal.

[0027] FIG. 4 shows examples of articles of clothing and garments that may be manufactured using the textiles and methods of the present disclosure. Protective suits 400 and 401 may be used by individuals who are regularly exposed to flames, such as firefighters. Such suits may be used in combination with protective head and neck coverings, such as head and neck covering 402. For example, the protective suits 400, 401 may be won over head and neck covering to limit skin exposure to flame. Often, meta-aramid and para-aramid garments are worn in such a manner that no skin is exposed, because the hazards faced by individuals wearing them include sustained exposure to extreme heat or fire. For these garments, ventilation in the form of openings in the fabric is undesirable because the heat or fire could burn the wearer of the garment through the openings.

[0028] FIG. 4 also shows a protective work shirt 403 that may be worn by individuals who may only be exposed to a infrequent or brief flame. These garments may be worn more loosely, and with more openings (such as button holes) than the full fire-protective described above. A protective work shirt 403 may comprise certain meta-aramid and para-aramid fibers blended with more traditional porous fabrics, such as cotton or polyester, in order to achieve an increased level of comfort and breathability. However, these traditional porous fabrics, when blended, may decrease the flame-resistant properties of the meta-aramid and para-aramid textile, because the porous fabrics let air and water through more easily than the meta-aramid and para-aramid fibers and are also not as flame resistant as the meta-aramid and para-aramid fibers. Incorporating traditional porous textile fibers into meta-aramid and para-aramid fibers typically decreases the flame resistance of the resulting blended textile as compared to a pure meta-aramid or para-aramid textile. In fact, adding too much of a traditional porous fabric can cause a meta-aramid or para-aramid blend to lose its self-extinguishing capability. In one embodiment, preferably less than 25%, more preferably less than 20%, and most preferably about 15% of the fiber in a porous/PET (or nylon) fiber and active particle embodiment, by weight, may comprise fibers doped with active particles. In contrast, composite textiles of the present disclosure can allow breathability and moisture management without substantially decreasing the flame resistance of the meta-aramid and para-aramid fibers. As a result, composite textiles of the present disclosure can be used advantageously in garments where ventilation openings are impractical and potentially dangerous, such as protective suits 400 and 401 and head coverings 402, providing breathability even in high fire-exposure environments. Additionally, composite textiles of the present disclosure may be used in combination with, or in place of blended meta-aramid or para-aramid garments, to provide increased flame resistance in more comfortable clothing such as the protective work shirt 403.

[0029] FIG. 5 is a graphical representation depicting the evaporation operation of a section of meta-aramid or para-aramid textile 501 without active particles and a section of meta-aramid or para-aramid textile 503 with active particles. As shown, moisture and humidity 502 on a first side 510 of the textile 501 is substantially blocked from escaping through to a second side 520 of the textile 501. FIG. 5 also shows a composite textile 503 comprising meta-aramid or para-aramid fibers with active particles integrated according to embodiments of the disclosure. As shown, moisture and humidity 504 can move from the first side 510 of the composite textile 503 to the second side 520. It is contemplated that the first side 510 and second side 520 of the textile 501, 503 seen in FIG. 5 may also refer to a first side and second side of the garments 400, 401, 402, and 403 seen in FIG. 4. In one embodiment, the first side of the FIG. 4 garments 400, 401, 402, and 403 may comprise a garment side nearest a person's body and a second side of the garments 400, 401, 402, and 403 may comprise a garment side nearest the ambient environment. Active particles may be distributed uniformly or non-uniformly between the meta-aramid or para-aramid fibers and throughout particular sections of the textile to provide a desired number of active particles per sweat pore located in that area.

[0030] Another aspect of the present disclosure provides a method by which active particles and meta-aramid or para-aramid fibers may be formed into a composite polymer textile. One method of manufacturing meta-aramid and para-aramid fibers is wet-spinning. Wet-spinning comprises a process in which a polymer/monomer is dissolved into a solvent, and the solution is spun using a spinneret, which precipitates or polymerizes the solution into a relatively flat fiber material. The material is eventually quenched into its solid form.

[0031] The method of the present disclosure may comprise dissolving polymers of meta-aramid or para-aramid into a solvent. Solutions of such dissolved polymers may be used in the process of wet-spinning to manufacture meta-aramid and para-aramid fibers, rather than heat-based extrusion methods of manufacturing, because once a meta-aramid or para-aramid polymer is formed, it does not melt into a liquid. One example of a solvent that may be used with the presently disclosed method includes sulfuric acid. Those skilled in the art can appreciate that solvents require particular characteristics in order to allow the polymer to dissolve into a solvent during the wet spinning process. Furthermore, an aspect of the present disclosure is that the active particles are insoluble and physically unaffected (not damaged) by the solvent. Therefore, in addition to the physical properties of active particles listed throughout the present disclosure, in some embodiments, the active particles may also have the additional property of being insoluble in certain known solvents. Alternatively, or additionally, in various embodiments of the method, a particular solvent may be chosen because it does not adversely impact the physical properties of a desired active particle.

[0032] One method may further comprise dispersing active particles into the solution. This dispersal may occur before or while the solution is being spun through a spinneret. The particles can be directly dispersed into the solution. Alternatively, the active particles may be dispersed using a dispersing agent. One type of dispersing agent may comprise Carbowet.RTM. from Air Products and Chemicals, Inc. 7201 Hamilton Blvd. Allentown Pa. 18195. Advantages to using a dispersing agent may be to achieve a higher level of uniformity of particle distribution, prevent particles from agglomerating, and prevent the particles from falling out of the dispersion. Falling out of a dispersion comprises a particle settling to the bottom of solution volume, preventing proper mixing of the solution. As another alternative, the active particles may be dispersed using a removable protective layer, such as an encapsulant, as described in U.S. Pat. No. 7,247,374, which is hereby incorporated by reference in its entirety. For example, when an active particle is coated with a protective layer, the protective layer may comprise a dispersing agent. Upon removal of the encapsulant from the active particle, or before, the encapsulant acts as a dispersing agent.

[0033] Upon dispersing the active particles in the solvent and then subsequently wet-spinning the solution, active particles may become physically incorporated and/or enmeshed with the meta-aramid or para-aramid fibers. Though the active particles may not form chemical bonds with the fibers, the two become physically intertwined. In the art, the dispersion of insoluble particles into a wet-spinning solution has not been pursued due to the knowledge that (i) active particles would not form chemical bonds with the tightly-aligned meta-aramid and para-aramid fibers and that (ii) the active particles would have a negative impact on the formation of the fibers. However, the method of the present disclosure results in the physical entanglement of the particles with the polymer fibers without negatively impacting the spinning process or the formation of the fibers. In fact, dispersion forces or van der Waals forces may also hold the active particles and meta-aramid or para-aramid fibers together. Seen in FIG. 6 are two microscopic views of active particles 601 as they would be physically incorporated with meta-aramid or para-aramid fibers 602, as described above. As shown, the active particles 601 are depicted as spots of varying sizes physically integrated with the fibers 602.

[0034] FIG. 7 shows a flowchart which may be implemented to perform a method 700 of the present disclosure. The method 700 starts at 704 and at step 701 the method may comprise dissolving a polymer into a solvent, which results in a liquid solution. Such a polymer may comprise a base monomer such as, but not limited to, polymers of meta-aramids and/or para-aramids. Then, at step 702, the method 700 may comprise dispersing active particles into the liquid solution. Next, at 703, the method 700 may further comprise wet-spinning the solution into a composite textile of aramid fibers and active particles. This may comprise polymerizing or precipitating the solution into a meta-aramid and/or para-aramid fiber material, along with physically incorporating the active particles into the fiber material. The method 700 ends at 705.

[0035] The active particles that are dispersed into the solution may be between 100 nm (0.1 microns) and 10 microns in size (e.g. average diameter). It is contemplated that in some embodiments, a given supply of active particles dispersed in a solution may be non-uniform in size. The 100 nm to 10 micron size range of active particles allows them to achieve certain properties. For example, activated carbon particles in the size range of at least 100 nm to may have a surface area greater than 10 m.sup.2/g, which allows for optimal moisture management characteristics of the resulting composite textile. Active particles of less than 10 microns in size may be sufficiently large to provide the desired characteristics while also being small enough to become entangled or enmeshed with the meta-aramid and para-aramid fibers during the wet-spinning manufacturing process.

[0036] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

* * * * *


uspto.report is an independent third-party trademark research tool that is not affiliated, endorsed, or sponsored by the United States Patent and Trademark Office (USPTO) or any other governmental organization. The information provided by uspto.report is based on publicly available data at the time of writing and is intended for informational purposes only.

While we strive to provide accurate and up-to-date information, we do not guarantee the accuracy, completeness, reliability, or suitability of the information displayed on this site. The use of this site is at your own risk. Any reliance you place on such information is therefore strictly at your own risk.

All official trademark data, including owner information, should be verified by visiting the official USPTO website at www.uspto.gov. This site is not intended to replace professional legal advice and should not be used as a substitute for consulting with a legal professional who is knowledgeable about trademark law.

© 2024 USPTO.report | Privacy Policy | Resources | RSS Feed of Trademarks | Trademark Filings Twitter Feed