U.S. patent application number 16/627115 was filed with the patent office on 2020-05-07 for reduced density synthetic fiber utilizing hollow microcapsules.
This patent application is currently assigned to PRIMALOFT, INC.. The applicant listed for this patent is PRIMALOFT, INC.. Invention is credited to Robert DEMPSEY, Vanessa MASON.
Application Number | 20200141029 16/627115 |
Document ID | / |
Family ID | 64746629 |
Filed Date | 2020-05-07 |
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United States Patent
Application |
20200141029 |
Kind Code |
A1 |
MASON; Vanessa ; et
al. |
May 7, 2020 |
REDUCED DENSITY SYNTHETIC FIBER UTILIZING HOLLOW MICROCAPSULES
Abstract
The invention provides a synthetic fiber that includes: 0.4 to
30 wt % hollow microcapsules having an average diameter of 4 to 30
.mu.m; and 70 to 99.6 wt % polymer material, wherein the synthetic
fiber has a denier of 0.1 to 11.0. Also provided are yarn,
insulation material, and articles that include the synthetic fiber,
and methods of making the same.
Inventors: |
MASON; Vanessa; (Rexford,
NY) ; DEMPSEY; Robert; (Mechanicville, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PRIMALOFT, INC. |
Latham |
NY |
US |
|
|
Assignee: |
PRIMALOFT, INC.
Latham
NY
|
Family ID: |
64746629 |
Appl. No.: |
16/627115 |
Filed: |
November 13, 2018 |
PCT Filed: |
November 13, 2018 |
PCT NO: |
PCT/US2018/060626 |
371 Date: |
December 27, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62586507 |
Nov 15, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D01D 5/247 20130101;
D01F 1/08 20130101; D01D 5/08 20130101; D01F 1/10 20130101; D01F
9/08 20130101; D01F 8/14 20130101 |
International
Class: |
D01D 5/247 20060101
D01D005/247; D01F 1/08 20060101 D01F001/08; D01F 8/14 20060101
D01F008/14; D01F 9/08 20060101 D01F009/08 |
Claims
1. A synthetic fiber comprising: 0.4 to 30 wt % hollow
microcapsules having an average diameter of 4 to 30 .mu.m; and 70
to 99.6 wt % polymer material, wherein the synthetic fiber has a
denier of 0.1 to 11.0.
2. The synthetic fiber according to claim 1, wherein the hollow
microcapsules are microspheres.
3. The synthetic fiber according to claim 1, wherein the
microcapsules are glass microspheres.
4. The synthetic fiber according to claim 1, wherein the
microcapsules are soda-lime borosilicate glass microspheres.
5. The synthetic fiber according to claim 1, wherein the synthetic
fiber is siliconized.
6. The synthetic fiber according to claim 1, comprising 7 to 15 wt
% of the hollow microcapsules.
7. The synthetic fiber according to claim 1, wherein the hollow
microcapsules have an average diameter of 5 to 20 .mu.m.
8. The synthetic fiber according to claim 7, wherein the hollow
microcapsules have an average diameter of 4 to 12 .mu.m.
9. The synthetic fiber according to claim 1, wherein the hollow
microcapsules are homogenously dispersed within the polymer
material.
10. The synthetic fiber according to claim 1, wherein the polymer
material comprises nylon, polyester, polypropylene, acrylic or
polyolefin polymer, or a combination thereof.
11. The synthetic fiber according to claim 10, wherein the polymer
material comprises polyester.
12. The synthetic fiber according to claim 11, wherein the
polyester is polyethylene terephthalate, polybutylene
terephthalate, or a combination thereof.
13. (canceled)
14. The synthetic fiber according to claim 1, having a denier of
0.7 to 6.0.
15. The synthetic fiber according to claim 1, wherein the fiber is
a staple fiber having a length of 5 to 120 mm.
16. (canceled)
17. The synthetic fiber according to claim 16, wherein the fiber is
crimped.
18. (canceled)
19. The synthetic fiber according to claim 1, additionally
comprising aerogel particles.
20. Insulation material comprising the synthetic fiber according to
claim 1.
21. Insulation material according to claim 20, wherein said
insulation material is blowable insulation or filling material,
comprising: a plurality of discrete, longitudinally elongated
floccules each formed of a plurality of the synthetic fibers, the
floccules including a relatively open enlarged medial portion and
relatively condensed twisted tail portions extending from opposing
ends of the medial portion.
22. An article comprising the synthetic fiber according to claim
1.
23. A method of making the synthetic fiber according to claim 1,
said method comprising: mixing the hollow microcapsules and the
polymer material, thereby forming a microcapsule/polymer mixture;
extruding the microcapsule/polymer mixture; and optionally
performing one or more additional processing steps, thereby forming
the synthetic fiber.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 62/586,507, filed on Nov. 15, 2017, the entire
contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to reduced density
synthetic fiber comprising polymer material and hollow
microcapsules, to insulation comprising the synthetic fiber, to
articles comprising the synthetic fiber, and to methods of forming
the synthetic fiber.
BACKGROUND OF THE INVENTION
[0003] The desirability and effectiveness of insulation materials
and articles comprising insulation materials are highly dependent
upon, e.g., the properties of fibers used to make the insulation.
Fibers have different physical properties depending on, inter alia,
their nature and composition. For example, natural fibers such as
wool fibers have different properties from polymeric fibers, and
polymeric fibers have different properties depending upon the
polymer(s) from which they are made. Keeping fiber denier and fiber
polymer material constant, achieving a lightweight article
typically depends on fabric construction and amount of fiber used.
Thus, available fiber technology can be a limiting variable in
terms of the number of viable construction alternatives for, inter
alia, lightweight articles.
[0004] Despite various advances in the textile field, a need
remains for fibers that are conducive to integration in articles
and insulation materials, and that provide desired properties (such
as thermal performance) yet also allow for reduced density, such
that the desired properties do not come at the expense of undesired
added weight.
[0005] While certain aspects of conventional technologies have been
discussed to facilitate disclosure of the invention, Applicant in
no way disclaims these technical aspects, and it is contemplated
that the claimed invention may encompass one or more conventional
technical aspects.
[0006] In this specification, where a document, act or item of
knowledge is referred to or discussed, this reference or discussion
is not an admission that the document, act or item of knowledge or
any combination thereof was, at the priority date, publicly
available, known to the public, part of common general knowledge,
or otherwise constitutes prior art under the applicable statutory
provisions; or is known to be relevant to an attempt to solve any
problem with which this specification is concerned.
SUMMARY OF THE INVENTION
[0007] Briefly, the present invention satisfies the need for
improved fiber having reduced density. In various embodiments, the
inventive fiber lends itself toward use in insulation that
demonstrates desired properties (e.g., thermal performance) without
undesirably increasing the weight of the insulation.
[0008] The present invention may address one or more of the
problems and deficiencies of the art discussed above. However, it
is contemplated that the invention may prove useful in addressing
other problems and deficiencies in a number of technical areas.
Therefore, the claimed invention should not necessarily be
construed as limited to addressing any of the particular problems
or deficiencies discussed herein.
[0009] In a first aspect, the invention provides a synthetic fiber
comprising: [0010] 0.4 to 30 wt % hollow microcapsules having an
average diameter of 4 to 30 .mu.m; and [0011] 70 to 99.6 wt %
polymer material, wherein the synthetic fiber has a denier of 0.1
to 11.0.
[0012] In a second aspect, the invention provides insulation
material comprising the synthetic fiber according to the first
aspect of the invention.
[0013] In a third embodiment, the invention provides an article
comprising the synthetic fiber according to the first aspect of the
invention.
[0014] In a fourth aspect, the invention provides a non-limiting
method of making the inventive synthetic fiber, insulation, or
article comprising the synthetic fiber, said method comprising:
[0015] mixing the hollow microcapsules and the polymer material,
thereby forming a microcapsule/polymer mixture; [0016] extruding
the microcapsule/polymer mixture; and [0017] optionally performing
one or more additional processing steps,
[0018] thereby forming the synthetic fiber.
[0019] Certain embodiments of the presently-disclosed synthetic
fiber, insulation and articles comprising the synthetic fiber, and
methods of making the synthetic fiber have several features, no
single one of which is solely responsible for their desirable
attributes. Without limiting the scope of the synthetic fiber,
insulation, articles, and methods as defined by the claims that
follow, their more prominent features will now be discussed
briefly. After considering this discussion, and particularly after
reading the section of this specification entitled "Detailed
Description of the Invention," one will understand how the features
of the various embodiments disclosed herein provide a number of
advantages over the current state of the art. For example, in some
embodiments, the synthetic fiber provides desired properties but at
reduced density relative to comparative fibers of like polymeric
composition and denier. Thus, in some embodiments, the inventive
fiber lends itself toward use in lightweight applications. In some
embodiments, the reduced density of the inventive fiber lends
itself toward advantageous use in, for example, yarn, woven and
nonwoven insulation materials, and articles (e.g., apparel,
footwear, bedding and industrial fabrics). Embodiments of the
synthetic fiber may offer low density construction and desirable
thermal performance suitable for use in, inter alia, making yarns,
fabrics, and insulation for apparel.
[0020] These and other features and advantages of this invention
will become apparent from the following detailed description of the
various aspects of the invention taken in conjunction with the
appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The present invention will hereinafter be described in
conjunction with the following drawing figures, which are not
necessarily drawn to scale, wherein the same reference numerals
retain their designation and meaning for the same or like elements
throughout the various drawings, and wherein:
[0022] FIG. 1 depicts an embodiment of a spherical glass hollow
microcapsule;
[0023] FIG. 2 depicts hollow microcapsule/polymer pellets according
to an embodiment of the present disclosure floating in water;
[0024] FIG. 3 is a side perspective view of a container with hollow
microcapsules mixed into polymer material according to certain
embodiments of the present disclosure;
[0025] FIG. 4 is an enlarged view of a synthetic fiber containing
hollow microcapsules according to certain embodiments of the
present disclosure;
[0026] FIG. 5 is a view of a polymer pellet containing hollow
microcapsules according to certain embodiments of the present
disclosure;
[0027] FIG. 6 is an enlarged, cross sectional view of the pellet of
FIG. 5 taken along line 6-6 according to certain embodiments of the
present disclosure;
[0028] FIG. 7A is a photograph of a microscope image of
cross-sections of fibers according to an embodiment of the present
disclosure; FIG. 7B is a simplified line drawing of cross-sections
of fibers according to an embodiment of the present disclosure;
[0029] FIG. 8A is a photograph of a microscope image of fibers
according to an embodiment of the present disclosure; and FIG. 8B
is a simplified line drawing of fibers according to an embodiment
of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Aspects of the present invention and certain features,
advantages, and details thereof, are explained more fully below
with reference to the non-limiting embodiments illustrated in the
accompanying drawings. Descriptions of well-known materials,
fabrication tools, processing techniques, etc., are omitted so as
to not unnecessarily obscure the invention in detail. It should be
understood, however, that the detailed description and the specific
example(s), while indicating embodiments of the invention, are
given by way of illustration only, and are not by way of
limitation. Various substitutions, modifications, additions and/or
arrangements within the spirit and/or scope of the underlying
inventive concepts will be apparent to those skilled in the art
from this disclosure.
[0031] Achieving a lightweight article has often come at the
expense of an undesirable sacrifice in one or more other properties
(e.g., thermal properties). The present invention addresses this
and other problems by integrating hollow microcapsules into polymer
material prior to making, for example, fabrics, insulation,
articles, etc. This is accomplished by forming hollow
microcapsules-comprising synthetic fiber. Embodiments of the
inventive synthetic fiber, and insulation and articles formed from
the synthetic fiber, may have, for example, reduced density, while
at the same time maintaining satisfactory desired other properties,
such as thermal performance and/or breathability. In some
embodiments, insulation and articles comprising the synthetic fiber
have good thermal properties and decreased density, as compared to
insulation and articles comprising the same fiber composition but
lacking hollow microcapsules.
[0032] In a first aspect, the invention provides a synthetic fiber
comprising: [0033] 0.4 to 30 wt % hollow microcapsules having an
average diameter of 4 to 30 .mu.m; and [0034] 70 to 99.6 wt %
polymer material, wherein the synthetic fiber has a denier of 0.1
to 11.0.
[0035] Denier is a unit of measure defined as the weight in grams
of 9000 meters of a fiber or yarn. It is a common way to specify
the weight (or size) of the fiber or yarn. For example, polyester
fibers that are 1.0 denier typically have a diameter of
approximately 10 micrometers. Micro-denier fibers are those having
a denier of 1.0 or less, while macro-denier fibers have a denier of
greater than 1.0.
[0036] The denier of the inventive synthetic fiber is 0.1 to 11.0
(e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2,
1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5,
2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8,
3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1,
5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4,
6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7,
7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0,
9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2,
10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, or 11.0 denier),
including any and all ranges and subranges therein (e.g., 0.7 to
10.0). For example, in some embodiments, the synthetic fiber has a
denier of 0.5 to 4.0 denier.
[0037] In some embodiments, the synthetic fiber comprises 0.4 to
30.0 wt % hollow microcapsules (e.g., 0.4, 0.5, 0.6, 0.7, 0.8, 0.9,
1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2,
2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5,
3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8,
4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1,
6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4,
7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7,
8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0,
10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1,
11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2,
12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3,
13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4,
14.5, 14.6, 14.7, 14.8, 14.9, 15.0, 15.1, 15.2, 15.3, 15.4, 15.5,
15.6, 15.7, 15.8, 15.9, 16.0, 16.1, 16.2, 16.3, 16.4, 16.5, 16.6,
16.7, 16.8, 16.9, 17.0, 17.1, 17.2, 17.3, 17.4, 17.5, 17.6, 17.7,
17.8, 17.9, 18.0, 18.1, 18.2, 18.3, 18.4, 18.5, 18.6, 18.7, 18.8,
18.9, 19.0, 19.1, 19.2, 19.3, 19.4, 19.5, 19.6, 19.7, 19.8, 19.9,
20.0, 20.1, 20.2, 20.3, 20.4, 20.5, 20.6, 20.7, 20.8, 20.9, 21.0,
21.1, 21.2, 21.3, 21.4, 21.5, 21.6, 21.7, 21.8, 21.9, 22.0, 22.1,
22.2, 22.3, 22.4, 22.5, 22.6, 22.7, 22.8, 22.9, 23.0, 23.1, 23.2,
23.3, 23.4, 23.5, 23.6, 23.7, 23.8, 23.9, 24.0, 24.1, 24.2, 24.3,
24.4, 24.5, 24.6, 24.7, 24.8, 24.9, 25.0, 25.1, 25.2, 25.3, 25.4,
25.5, 25.6, 25.7, 25.8, 25.9, 26.0, 26.1, 26.2, 26.3, 26.4, 26.5,
26.6, 26.7, 26.8, 26.9, 27.0, 27.1, 27.2, 27.3, 27.4, 27.5, 27.6,
27.7, 27.8, 27.9, 28.0, 28.1, 28.2, 28.3, 28.4, 28.5, 28.6, 28.7,
28.8, 28.9, 29.0, 29.1, 29.2, 29.3, 29.4, 29.5, 29.6, 29.7, 29.8,
29.9, or 30.0 wt %), including any and all ranges and subranges
therein (e.g., 15 to 25 wt %, 5 to 20 wt %, 7 to 12 wt %,
etc.).
[0038] In some embodiments, the hollow microcapsules have an
average diameter of 4 to 30 .mu.m (e.g., 4, 5, 6, 7, 8, 9, 10, 11,
12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28,
29, or 30 .mu.m), including any and all ranges and subranges
therein (e.g., 5 to 20 .mu.m, 5 to 18 .mu.m, 4 to 12 .mu.m, 4 to 11
.mu.m, 4 to 10 .mu.m, etc.). As used herein, the "diameter" of a
microcapsule refers to a straight line passing from side to side
through the center of the microcapsule. Where the microsphere is
non-spherical, the diameter refers to a straight line passing from
side to side through the center of the microcapsule at the largest
dimension (e.g., for an ovoid-shaped microcapsule, the diameter
would be the straight line passing from side to side through the
center of the microcapsule along the longitudinal (longest)
dimension of the body).
[0039] In some embodiments, at least 90% (e.g., at least 91, 92,
93, 94, 95, 96, 97, 98, 99, 99.5, or 99.9%) of the hollow
microcapsules present in the inventive fiber have sizes of less
than 20 .mu.m (e.g., less than 19, 18, 17, 16, 15, 14, 13, 12, 11,
or 10 .mu.m).
[0040] As used herein, the term "hollow microcapsule" refers to a
body having a continuous outer shell that defines an empty space
inside of the shell. FIG. 1 depicts an embodiment of a spherical
glass hollow microcapsule 10. Microcapsule 10 is a microsphere
(i.e., the microcapsule has a spherical shape) made of glass (e.g.,
borosilicate glass), i.e., outer shell 12 is made of glass. The
outer shell 12 defines a hollow inner portion 14. Microcapsule 10
has a diameter Y, which is about 4 to 30 .mu.m.
[0041] The hollow microcapsules used in the inventive fiber can
have various shapes. In some non-limiting embodiments, the hollow
microcapsules comprise microcapsules having a spherical, ovoid,
ellipsoid, prolate (elongated) spheroid, oblate (flattened)
spheroid, cylindrical shape, or any variation or combination
thereof. In some embodiments, the hollow microcapsules are
substantially spherical (e.g., the average shape of the hollow
microcapsules is spheroid). In some embodiments, the hollow
microcapsules are spherical (i.e., the hollow microcapsules are
microspheres).
[0042] The microcapsules may be of any art-acceptable desired
composition. In some embodiments, the microcapsules are inorganic
glass microcapsules (i.e., the outer shell surrounding the inner
hollow portion of the microcapsule is made of glass). In some
embodiments, the microcapsules are borosilicate glass
microcapsules. For example, in some embodiments, the microcapsules
are soda-lime borosilicate glass microcapsules.
[0043] In some embodiments, the microcapsules have an average
density, of, e.g., from 0.15 to 0.90 g/cm.sup.3 (e.g., 0.15, 0.16,
0.17, 0.18, 0.19, 0.20, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27,
0.28, 0.29, 0.30, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38,
0.39, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49,
0.50, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58, 0.59, 0.60,
0.61, 0.62, 0.63, 0.64, 0.65, 0.66, 0.67, 0.68, 0.69, 0.70, 0.71,
0.72, 0.73, 0.74, 0.75, 0.76, 0.77, 0.78, 0.79, 0.80, 0.81, 0.82,
0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, or 0.90 g/cm.sup.3),
including any and all ranges and subranges therein (e.g., 0.1 to
0.8 g/cm.sup.3, 0.2 to 0.75 g/cm.sup.3, 0.3 to 0.60 g/cm.sup.3,
etc.).
[0044] The synthetic fiber comprises 70 to 99.6 weight % polymer
material (e.g., 70.0, 70.1, 70.2, 70.3, 70.4, 70.5, 70.6, 70.7,
70.8, 70.9, 71.0, 71.1, 71.2, 71.3, 71.4, 71.5, 71.6, 71.7, 71.8,
71.9, 72.0, 72.1, 72.2, 72.3, 72.4, 72.5, 72.6, 72.7, 72.8, 72.9,
73.0, 73.1, 73.2, 73.3, 73.4, 73.5, 73.6, 73.7, 73.8, 73.9, 74.0,
74.1, 74.2, 74.3, 74.4, 74.5, 74.6, 74.7, 74.8, 74.9, 75.0, 75.1,
75.2, 75.3, 75.4, 75.5, 75.6, 75.7, 75.8, 75.9, 76.0, 76.1, 76.2,
76.3, 76.4, 76.5, 76.6, 76.7, 76.8, 76.9, 77.0, 77.1, 77.2, 77.3,
77.4, 77.5, 77.6, 77.7, 77.8, 77.9, 78.0, 78.1, 78.2, 78.3, 78.4,
78.5, 78.6, 78.7, 78.8, 78.9, 79.0, 79.1, 79.2, 79.3, 79.4, 79.5,
79.6, 79.7, 79.8, 79.9, 80.0, 80.1, 80.2, 80.3, 80.4, 80.5, 80.6,
80.7, 80.8, 80.9, 81.0, 81.1, 81.2, 81.3, 81.4, 81.5, 81.6, 81.7,
81.8, 81.9, 82.0, 82.1, 82.2, 82.3, 82.4, 82.5, 82.6, 82.7, 82.8,
82.9, 83.0, 83.1, 83.2, 83.3, 83.4, 83.5, 83.6, 83.7, 83.8, 83.9,
84.0, 84.1, 84.2, 84.3, 84.4, 84.5, 84.6, 84.7, 84.8, 84.9, 85.0,
85.1, 85.2, 85.3, 85.4, 85.5, 85.6, 85.7, 85.8, 85.9, 86.0, 86.1,
86.2, 86.3, 86.4, 86.5, 86.6, 86.7, 86.8, 86.9, 87.0, 87.1, 87.2,
87.3, 87.4, 87.5, 87.6, 87.7, 87.8, 87.9, 88.0, 88.1, 88.2, 88.3,
88.4, 88.5, 88.6, 88.7, 88.8, 88.9, 89.0, 89.1, 89.2, 89.3, 89.4,
89.5, 89.6, 89.7, 89.8, 89.9, 90.0, 90.1, 90.2, 90.3, 90.4, 90.5,
90.6, 90.7, 90.8, 90.9, 91.0, 91.1, 91.2, 91.3, 91.4, 91.5, 91.6,
91.7, 91.8, 91.9, 92.0, 92.1, 92.2, 92.3, 92.4, 92.5, 92.6, 92.7,
92.8, 92.9, 93.0, 93.1, 93.2, 93.3, 93.4, 93.5, 93.6, 93.7, 93.8,
93.9, 94.0, 94.1, 94.2, 94.3, 94.4, 94.5, 94.6, 94.7, 94.8, 94.9,
95.0, 95.1, 95.2, 95.3, 95.4, 95.5, 95.6, 95.7, 95.8, 95.9, 96.0,
96.1, 96.2, 96.3, 96.4, 96.5, 96.6, 96.7, 96.8, 96.9, 97.0, 97.1,
97.2, 97.3, 97.4, 97.5, 97.6, 97.7, 97.8, 97.9, 98.0, 98.1, 98.2,
98.3, 98.4, 98.5, 98.6, 98.7, 98.8, 98.9, 99.0, 99.1, 99.2, 99.3,
99.4, 99.5, or 99.6 wt % polymer material), including any and all
ranges and subranges therein.
[0045] The polymer material used in the synthetic fiber comprises
any desired polymer matrix within which the hollow microcapsules
are comprised. For example, in some embodiments the polymer
material is selected from polyester, nylon, acrylic, polylactic
acid (also known as polylactide) (PLA), polyolefin, acetate,
aramid, lyocell, spandex, viscose, modal, polypropylene, polyamide,
poly(butyl acrylate) (PBA), acrylate, rayon, and combinations
thereof. In particular embodiments, the polymer material comprises
polyester. In certain embodiments, the polymer material comprises
PET or PBT.
[0046] In some embodiments, the polymer material is or comprises a
thermoplastic polymer (e.g., a polyester elastomer, such those
marketed by Hytrel, e.g., Hytrel Type 5556).
[0047] In some embodiments, the polymer material is or comprises a
thermoplastic polymer having properties similar to those of the
Hytrel Type 5556 polyester elastomer. For example, in some
embodiments, the polymer material is or comprises a polymer having
one or more quantifiable properties, P.sub.i, in the range of
P.sub.5556+/-0.15P.sub.5556, wherein P.sub.i is the property of the
material used in the inventive fiber, and P.sub.5556 is the
corresponding property of the Hytrel Type 5556 polyester elastomer
(so, e.g., the 5556 product has a density of 1.19 g/cc, thus, in
some embodiments the inventive fiber comprises polymeric material
having a density of 1.19 g/cc+/-0.18 g/cc).
[0048] In some embodiments, the polymer material comprises
polyester, wherein said polyester is selected from polyethylene
terephthalate (PET), poly(hexahydro-p-xylylene terephthalate),
polybutylene terephthalate (PBT), poly-1,4-cyclohexelyne
dimethylene (PCDT) and terephthalate copolyesters in which at least
85 mole percent of the ester units are ethylene terephthalate or
hexahydro-p-xylylene terephthalate units. In a particular
embodiment, the polyester is polyethylene terephthalate.
[0049] In some embodiments, the polymer material comprises recycled
polymer material, for example, post-consumer recycled (PCR) or
post-industrial recycled (PIR) material.
[0050] In some embodiments, the polymer material comprises recycled
polyester (e.g., recycled PET or PBT).
[0051] Embodiments of the inventive synthetic fiber provide
polymeric fibers within which hollow microcapsules are embedded in
polymer material. In some embodiments, the hollow microcapsules are
homogenously mixed within the polymer material, meaning, the
mixture of polymer material and hollow microcapsules comprised
within the synthetic fiber has a substantially uniform (i.e.,
90-100% uniform, e.g., at least 90.0, 90.1, 90.2, 90.3, 90.4, 90.5,
90.6, 90.7, 90.8, 90.9, 91.0, 91.1, 91.2, 91.3, 91.4, 91.5, 91.6,
91.7, 91.8, 91.9, 92.0, 92.1, 92.2, 92.3, 92.4, 92.5, 92.6, 92.7,
92.8, 92.9, 93.0, 93.1, 93.2, 93.3, 93.4, 93.5, 93.6, 93.7, 93.8,
93.9, 94.0, 94.1, 94.2, 94.3, 94.4, 94.5, 94.6, 94.7, 94.8, 94.9,
95.0, 95.1, 95.2, 95.3, 95.4, 95.5, 95.6, 95.7, 95.8, 95.9, 96.0,
96.1, 96.2, 96.3, 96.4, 96.5, 96.6, 96.7, 96.8, 96.9, 97.0, 97.1,
97.2, 97.3, 97.4, 97.5, 97.6, 97.7, 97.8, 97.9, 98.0, 98.1, 98.2,
98.3, 98.4, 98.5, 98.6, 98.7, 98.8, 98.9, 99.0, 99.1, 99.2, 99.3,
99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% uniform) composition.
[0052] Within the synthetic fiber, the hollow microcapsules may be,
for example, completely or at least partially covered by the
polymer material. In some embodiments, the majority of hollow
microcapsules present (i.e., greater that 50%, e.g., greater than
51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67,
68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84,
85, 86, 87, 88, 89, 90, 91, 92, 93, 94, or 95%) are completely
covered by the polymer material.
[0053] In certain embodiments, the inventive synthetic fiber has a
lower weight to volume ratio when compared to fibers having similar
composition, but lacking the hollow microcapsules.
[0054] In some embodiment, the inventive synthetic fiber has a
density of 0.7 to 1.35 grams per cubic centimeter (g/cc) (e.g.,
0.70, 0.71, 0.72, 0.73, 0.74, 0.75, 0.76, 0.77, 0.78, 0.79, 0.80,
0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91,
0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.0, 1.01, 1.02,
1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,
1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24,
1.25, 1.26, 1.27, 1.28, 1.29, 1.30, 1.31, 1.32, 1.33, 1.34, or 1.35
g/cc), including any and all ranges and subranges therein (e.g.,
0.80 to 1.30 g/cc, 0.82 to 1.20 g/cc, 0.83 to 1.15 g/cc, 0.85 to
1.12 g/cc, 0.90 to 1.10 g/cc, etc.).
[0055] In some embodiments, the synthetic fiber is siliconized. The
term "siliconized" means that the fiber is coated with a
silicon-comprising composition (e.g., a silicone). Siliconization
techniques are well known in the art, and are described, e.g., in
U.S. Pat. No. 3,454,422. The silicon-comprising composition may be
applied using any method known in the art, e.g., spraying, mixing,
dipping, padding, etc. The silicon-comprising (e.g., silicone)
composition, which may include an organosiloxane or polysiloxane,
bonds to an exterior portion of the fiber. In some embodiments, the
silicone coating is a polysiloxane such as a
methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane,
polydimethylsiloxane, or amino modified dimethylpolysiloxane. As is
known in the art, the silicon-comprising composition may be applied
directly to the fiber, or may be diluted with a solvent as a
solution or emulsion, e.g. an aqueous emulsion of a polysiloxane,
prior to application. Following treatment, the coating may be dried
and/or cured. As is known in the art, a catalyst may be used to
accelerate the curing of the silicon-comprising composition (e.g.,
polysiloxane containing Si--H bonds) and, for convenience, may be
added to a silicon-comprising composition emulsion, with the
resultant combination being used to treat the synthetic fiber.
Suitable catalysts include iron, cobalt, manganese, lead, zinc, and
tin salts of carboxylic acids such as acetates, octanoates,
naphthenates and oleates. In some embodiments, following
siliconization, the fiber may be dried to remove residual solvent
and then optionally heated to between 65.degree. and 200.degree. C.
to cure.
[0056] The synthetic fiber may be crimped or uncrimped. Various
crimps, including spiral (i.e., helical) and standard crimp, are
known in the art. The synthetic fiber may have any desired
crimp.
[0057] In some embodiments, the synthetic fiber is a staple fiber
(i.e., a fiber having a standardized length). For example, in some
embodiments, the synthetic fiber is a staple fiber having a length
of 5 to 120 mm (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33,
34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50,
51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67,
68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84,
85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100,
101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113,
114, 115, 116, 117, 118, 119, or 120 mm), including any and all
ranges and subranges therein (e.g., 8 to 85 mm). In some
embodiments, the invention provides a plurality of staple
fibers.
[0058] In some embodiments, the synthetic fiber is a filament. A
filament is a single long threadlike continuous textile
fiber/strand. Unlike staple fibers, which are of finite length,
filaments are of indefinite length, and can run for yards or miles
(or e.g., where employed in yarn, can run the entire length of
yarn). In some embodiments, the filament ranges in length from 5
inches to several miles, including any and all ranges and subranges
therein. For example, in some embodiments, the filament may be at
least 5 inches in length (e.g., at least 5, 6, 7, 8, 9, 10, 11, 12,
13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29,
30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46,
47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63,
64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80,
81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97,
98, 99, or 100 inches in length, or any range or subrange therein).
In some embodiments, the filaments may be at least 1 foot in length
(e.g., at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15,
16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32,
33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49,
50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66,
67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83,
84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99,
100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220,
230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350,
360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480,
490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610,
620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740,
750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870,
880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, or 1000
feet in length, or any range or subrange therein).
[0059] Filaments may be created by a process known as extrusion
(which can also be called melt spinning). For example, in some
embodiments, after mixing hollow microcapsules and polymer
material, the resultant hollow microcapsules/polymer mixture may be
extruded as a hollow microcapsules/polymer pellet. Subsequently,
depending on desired hollow microcapsule loading, a plurality of
pellets, including at least the hollow microcapsules/polymer
pellet, may be extruded into fiber. For example, pellets can be
extruded through well-known techniques, such as by bringing them to
or beyond their melting point, thereby forming liquid hollow
microcapsules/polymer mixture, then forcing the liquid hollow
microcapsules/polymer mixture through a dye called a spinneret. The
spinneret often has many small holes through which the liquid
passes. The liquid polymer streams are cooled upon exiting the
spinneret, resulting in long strands of continuous synthetic
fibers. The extruded filaments may optionally be combined with
those of another (e.g., an adjoining) spinneret to increase the
number of filaments in a bundle. A bundle of filaments may be drawn
(stretched) to make each filament thinner, and may optionally be
texturized, as described below.
[0060] Texturizing techniques may be performed on filament bundles
(used, e.g., in yarn) to disrupt the parallelization of the
filaments. Such techniques may serve, for example, to add bulk
without adding weight, which can make the resultant yarn seem
lighter in weight, have improved hand-feel (softness), appear more
opaque, and/or have improved temperature insulating properties.
While any art-acceptable texturizing processes may be employed,
examples of texturizing processes conducive to use in the invention
include crimping, looping, coiling, crinkling, twisting then
untwisting and knitting then deknitting.
[0061] In some embodiments, the synthetic fiber comprises a
lubricious additive, such as that disclosed in U.S. Pat. No.
3,324,060. In some embodiments, the synthetic fiber does not
comprise a lubricious additive, such as that disclosed in U.S. Pat.
No. 3,324,060.
[0062] In some embodiments, the synthetic fiber additionally
comprises one or more additional additives. For example, in some
embodiments, the synthetic fiber additionally comprises aerogel.
For example, in some embodiments, the synthetic fiber additionally
comprises aerogel particles, as in, e.g., the synthetic fiber
described in International Application Publication No. WO
2017/087511. For example, in some embodiments, the inventive fiber
comprises 0.1 to 15 wt % aerogel particles, including any and all
ranges and subranges therein (e.g., 1 to 10 wt %, 0.5 to 4.5 wt %,
1 to 4.5 wt %, 2 to 4.5 wt %, etc.), said aerogel particles having
an average diameter of 0.3 to 20 including any and all ranges and
subranges therein (e.g., 0.8 to 2 .mu.m).
[0063] Persons having ordinary skill in the art will readily
appreciate that there are many applications within which the
inventive synthetic fiber may be advantageously employed. Indeed,
embodiments of the synthetic fiber and insulation according to the
invention find use in many different industries.
[0064] In a second aspect, the invention provides insulation
material comprising the synthetic fiber according to the first
aspect of the invention.
[0065] In some embodiments, the insulation material is batting.
[0066] In some embodiments, the insulation material is blowable
insulation or filling material.
[0067] In some embodiments, the insulation material is blowable
insulation or filling material, comprising a plurality of discrete,
longitudinally elongated floccules each formed of a plurality of
synthetic fibers according to an embodiment of the invention, the
floccules including a relatively open enlarged medial portion and
relatively condensed twisted tail portions extending from opposing
ends of the medial portion. For examples, in some embodiments, the
insulation material is a blowable floccule insulation as described
in International Application Publication No. WO 2017/058986, which
comprises the inventive fiber.
[0068] Persons having ordinary skill in the art will appreciate
that the inventive fiber may generally be used in place of or in
supplement to synthetic fiber used in any insulation material.
[0069] In some embodiments, the insulation material is fabric,
fleece, a pad, blowable insulation material or batting. In some
embodiments, the insulation material is textile insulation material
(i.e., insulation material used in the textile field). In some
embodiments, the insulation material is insulation material used in
home goods (e.g., cushions, pillows, beds, bedding, etc.).
[0070] In some embodiments, the invention provides batting
comprising the synthetic fiber. In some embodiments, the batting
has a thickness of 1 mm to 160 mm (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9,
10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26,
27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43,
44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60,
61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77,
78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94,
95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108,
109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121,
122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134,
135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147,
148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, or 160
mm), including any and all ranges and subranges therein. In some
embodiments, the thickness is less than or equal to 40 mm, e.g., 2
to 40 mm. In some embodiments, the batting has a density of 1 to 10
kg/m.sup.3 (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 kg/m.sup.3),
including any and all ranges and subranges therein.
[0071] In some embodiments, the insulation material is yarn
comprising the inventive synthetic fiber.
[0072] In a third aspect, the invention provides an article
comprising the synthetic fiber of the first aspect of the
invention, or the insulation material of the second aspect of the
invention.
[0073] In some non-limiting embodiments, the article is an article
of footwear (e.g., shoes, socks, slippers, boots), outerwear (e.g.
outerwear garments such as a jacket, coat, shoe, boot, pants (e.g.,
snow pants, ski pants, etc.) glove, mitten, scarf, hat, etc.),
clothing/apparel (e.g., shirts, pants, undergarments (e.g.,
underwear, thermal underwear, socks, hosiery, etc.), sleepwear
(e.g., pajamas, nightgown, robe, etc.)), active wear (e.g.,
clothing, including footwear, worn for sport or physical exercise),
sleeping bag, bedding (e.g., comforter), pillow, cushion, pet bed,
home good, etc. In some embodiments, the inventive fiber is
comprised within at least a part of one of the articles listed
above.
[0074] In a fourth aspect, the invention provides a non-limiting
method of making the inventive synthetic fiber, insulation, or
article comprising the synthetic fiber, said method comprising:
[0075] mixing the hollow microcapsules and the polymer material,
thereby forming a microcapsule/polymer mixture; [0076] extruding
the microcapsule/polymer mixture; and [0077] optionally performing
one or more additional processing steps,
[0078] thereby forming the synthetic fiber.
[0079] In some embodiments, during said mixing the hollow
microcapsules and the polymer material, both the hollow
microcapsules and the polymer material are dry.
[0080] In some embodiments, said extruding the hollow
microcapsules/polymer mixture comprises subjecting a dry hollow
microcapsules/polymer mixture to a melt extrusion process, thereby
forming a hollow microcapsules/polymer pellet or fiber.
[0081] In some embodiments, said additional processing steps
comprise forming the synthetic fiber from the microcapsules/polymer
pellet.
[0082] In some embodiments, the hollow microcapsules/polymer pellet
is extruded so as to form the synthetic fiber.
[0083] In some embodiments, extruding the microcapsule/polymer
mixture forms a fiber of denier X, and wherein the method further
comprising drawing the fiber of denier X in one or more drawing
steps, thereby converting the fiber of denier X to a fiber of
denier Y, wherein Y<X. In some embodiments, Y.ltoreq.0.7X.
[0084] In some embodiments, the inventive method comprises 1, 2, 3,
4, or more drawing steps. The drawing step(s) may be any drawing
steps. For example, in some embodiments, the drawing steps
comprise, e.g., hot water quench drawing and/or hot oven
drawing.
[0085] In some embodiments, solid polymer material is obtained in
pre-ground form, or the polymer material is grinded, such that the
polymer material is in the form of particles. In some embodiments,
the polymer material is ground polymer material that resembles the
consistency of sand. Hollow microcapsules of a desired size are
mixed with the polymer material to form a microcapsule/polymer
mixture. The weight concentration of microcapsules to polymer may
be selected for the desired properties of the resultant fibers.
[0086] The microcapsule/polymer mixture may then be extruded or
otherwise formed into an intermediary product (e.g., as
microcapsule/polymer pellets 22, as depicted as depicted in FIG. 2,
which have a density of 0.86 g/cm.sup.3) that can later be used to
make fiber. In some embodiments (discussed in more detail below),
this intermediary product may be referred to as a "master batch."
In other embodiments, the microcapsule/polymer mixture may be
directly extruded into fiber. Where an intermediary product (e.g.,
microcapsule/polymer pellets) is made, the intermediary product may
optionally later be mixed with other material (e.g., other polymer
material or other pellets that comprise a different microcapsule
loading, or no microcapsules) so as to control and achieve a
desired loading percent of microcapsule in subsequently-formed
fiber.
[0087] Embodiments of the inventive method comprise forming fiber,
either directly from the microcapsule/polymer mixture, or from the
intermediary products (e.g., pellets), using appropriate textile
fiber production methods, as are well known in the art. The textile
fiber production method may include, for example, melt spinning,
wet spinning, dry spinning, gel spinning, electro spinning, and the
like as known in the art. For example, a mixture (e.g., the
microcapsule/polymer mixture, or a mixture containing the
intermediary products--for example, a mixture comprising melted
intermediary products and optionally one or more other materials)
may be extruded through spinnerets to form continuous filaments.
The continuous filaments may then be manipulated by, for example,
drawing, texturizing, crimping, and/or cutting, or another known
method in the art, to form fibers in the most usable form for their
final application. The continuous filaments may be cut to a
specific length and packaged into a bale. The bale may then be
sent, e.g., to a yarn spinner that processes the staple fibers into
yarn (which could be further processed, e.g., for use in apparel
such as base layer garments).
[0088] Processing steps undertaken to form the synthetic fiber or
articles comprising the synthetic fiber can differ depending on the
fiber that is intended to be formed. For example, in some
embodiments, the inventive process forms a continuous filament by,
e.g., drawing, texturizing, and optionally adding one or more
desired finish chemistries. In some embodiments, the method forms
staple fibers by, e.g., drawing, cutting, optionally crimping, and
optionally adding one or more desired finish chemistries. It is
contemplated that any desired finish chemistries may be used in
accordance with the invention. Finish chemistries are well known in
the art and include, e.g., siliconization, durable water repellency
treatment, etc.
[0089] The synthetic fiber may be incorporated into articles (e.g.,
end products), for example, garments, fabric, or insulation.
[0090] In some embodiments of the inventive method, the hollow
microcapsules are introduced into a polymer material, and, once
mixed, the microcapsule/polymer mixture may be extruded into
pellets (e.g., pellets 22 in FIG. 2), which may be referred to as a
"master batch". The master batch may be transferred to a
manufacturer for extruding (e.g., melt blown spinning). The master
batch may be used to produce fibers. In some embodiments, the
master batch is used to produce a fibrous, non-woven batting of
filaments. In some embodiments, the master batch may be combined
with pellets of other formulations to produce a desired material
for use in fibers according to embodiments of the invention.
[0091] With reference to FIGS. 3-6, an embodiment of a method of
mixing polymer material with hollow microcapsules, as described in
greater detail above, is shown. The method includes mixing a
polymer material 110 (any desired polymer, e.g., polyester pellets
that are ground down to a sand-like consistency), with hollow
microcapsules 120 so as to form a microcapsule/polymer mixture 100,
as shown in FIG. 3, wherein the hollow microcapsules 120 are mixed
within the polymer material 110. In some embodiments, the mixture
can comprise any additional additives, but in some embodiments, the
mixture does not comprise additional additives. The mixture may be
extruded into fiber 130 (which may be a filament or may be cut to
staple fiber) as depicted in FIG. 4, or formed into pellets 140, as
described in greater detail above and shown in FIGS. 5 and 6. Where
the mixture is melt-extruded into pellets 140, the pellets may
optionally be combined with additional pellets (to control
microcapsule and any additional additive loading, e.g., aerogel
loading), and may subsequently be extruded into fibers.
[0092] An embodiment of the inventive synthetic fiber 130 is
illustrated in FIG. 4. As shown, the polymer material 110 of the
synthetic fiber 130 contains a plurality of hollow microcapsules
120 dispersed throughout the polymer material 110. The
microcapsules 120 may be homogeneously distributed throughout the
polymer material 110. Although FIG. 4 shows the microcapsules 120
completely embedded into the polymer material 110, it is also
contemplated that in some instances the microcapsules 120 may be
only at least partially embedded into the polymer material 110. The
weight percentage of microcapsules 120 dispersed throughout the
polymer material 110 will be dependent upon the desired properties
(including weight) of the resultant synthetic fiber 130.
[0093] The pellets containing hollow microcapsule/polymer mixture
140, are illustrated in FIGS. 5 and 6. As shown, the pellets 140
contain a plurality of hollow microcapsules 120 dispersed
throughout the polymer material 110. The hollow microcapsules 120
may be homogeneously distributed throughout the polymer material
110, as shown in FIGS. 5 and 6. Although FIGS. 5 and 6 show the
hollow microcapsules 120 completely embedded into the polymer
material 110, it is also contemplated that in some instances the
hollow microcapsules 120 may be only at least partially embedded
into the polymer material 110 in some locations of the pellets 140.
The weight percentage of hollow microcapsules 120 dispersed
throughout the polymer material 110 will be dependent upon the
desired properties of the resultant fiber or insulation made from
the pellets 140.
EXAMPLES
[0094] The invention will now be illustrated, but not limited, by
reference to the specific embodiments described in the following
examples.
Example 1
[0095] A hollow microcapsules/polymer mixture is prepared by mixing
the following: [0096] 30% by weight glass microspheres having
diameters of 17 micron or less; and [0097] 70% by weight polyester
elastomer (Hytrel 5556).
[0098] After being mixed/blended, the hollow microcapsules/polymer
mixture is then extruded into pellets, which are subsequently mixed
with polyester pellets. The pellet mix is later heated and extruded
through a spinning method, for example spinnerets, to form
continuous filaments. Once the continuous filaments are formed,
they may be drawn, crimped, and/or cut to a specific length to form
staple fibers which are then packaged into bale, which may be
optionally sent to a yarn spinner for the staple fibers to be
processed into yarns. The yarns may then be used downstream to
create an article, such as, apparel and industrial fabrics. The
yarns and insulation made from the synthetic fiber containing the
polymer material and hollow microcapsules allow for fabrics and
articles having reduced density.
[0099] FIG. 7A is a photograph of a microscope image of cross
sections of fibers 130, which are polymer material 110 (polyester
fibers made from the Hytrel 5556) comprising soda-lime borosilicate
microspheres 120. The fibers 130 are 10 denier fibers.
[0100] FIG. 7B is a simplified line drawing of cross sections of
fibers 130, which are polymer material 110 comprising microspheres
120.
[0101] FIG. 8A is a photograph of a microscope image of portions of
fibers 130 comprising polyester polymer material 110 with soda-lime
borosilicate microspheres 120 having a diameter of less than 20
.mu.m comprised within.
[0102] FIG. 8B is simplified line drawing of portions of fibers 130
comprising polymer material 110 with microspheres 120 having a
diameter of less than 20 .mu.m comprised within.
Example 2
[0103] A hollow microcapsules/polymer mixture is prepared by mixing
the following: [0104] 25% by weight glass microspheres having
diameters of 13 micron or less; and [0105] 75% by weight
polybutylene terephthalate (PBT).
[0106] After being mixed/blended, the hollow microcapsules/polymer
mixture is then extruded into master batch (MB) pellets, which are
subsequently mixed with polybutylene terephthalate (PBT) pellets
and extruded into fiber. The subsequent fiber blend ratio is 25:75
(MB:PBT).
[0107] After extrusion, spinning, and drawing processing steps, a
4.6 denier per filament (dpf) fiber was produced having a density
range of 0.95-1.10 g/cc.
[0108] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprise" (and any form of comprise, such as
"comprises" and "comprising"), "have" (and any form of have, such
as "has" and "having"), "include" (and any form of include, such as
"includes" and "including"), "contain" (and any form contain, such
as "contains" and "containing"), and any other grammatical variant
thereof, are open-ended linking verbs. As a result, a method or
article that "comprises", "has", "includes" or "contains" one or
more steps or elements possesses those one or more steps or
elements, but is not limited to possessing only those one or more
steps or elements. Likewise, a step of a method or an element of an
article that "comprises", "has", "includes" or "contains" one or
more features possesses those one or more features, but is not
limited to possessing only those one or more features.
[0109] As used herein, the terms "comprising," "has," "including,"
"containing," and other grammatical variants thereof encompass the
terms "consisting of" and "consisting essentially of."
[0110] The phrase "consisting essentially of" or grammatical
variants thereof when used herein are to be taken as specifying the
stated features, integers, steps or components but do not preclude
the addition of one or more additional features, integers, steps,
components or groups thereof but only if the additional features,
integers, steps, components or groups thereof do not materially
alter the basic and novel characteristics of the claimed
compositions or methods.
[0111] All publications cited in this specification are herein
incorporated by reference as if each individual publication were
specifically and individually indicated to be incorporated by
reference herein as though fully set forth.
[0112] Subject matter incorporated by reference is not considered
to be an alternative to any claim limitations, unless otherwise
explicitly indicated.
[0113] Where one or more ranges are referred to throughout this
specification, each range is intended to be a shorthand format for
presenting information, where the range is understood to encompass
each discrete point within the range as if the same were fully set
forth herein.
[0114] While several aspects and embodiments of the present
invention have been described and depicted herein, alternative
aspects and embodiments may be affected by those skilled in the art
to accomplish the same objectives. Accordingly, this disclosure and
the appended claims are intended to cover all such further and
alternative aspects and embodiments as fall within the true spirit
and scope of the invention.
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