U.S. patent application number 16/862457 was filed with the patent office on 2020-10-29 for method to incorporate particles in natural fibers and materials.
The applicant listed for this patent is Cocona, Inc.. Invention is credited to Gregory W. Haggquist, Devin Muldoon, Rachel Vinson.
Application Number | 20200340174 16/862457 |
Document ID | / |
Family ID | 1000004944282 |
Filed Date | 2020-10-29 |
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United States Patent
Application |
20200340174 |
Kind Code |
A1 |
Haggquist; Gregory W. ; et
al. |
October 29, 2020 |
METHOD TO INCORPORATE PARTICLES IN NATURAL FIBERS AND MATERIALS
Abstract
Embodiments of the present invention relate to materials
containing performance-enhancing particles. In particular, but not
by way of limitation, the invention is related to mechanically
attaching a performance-enhancing particle to various substrates
including, but not limited to, natural materials such as cotton,
wool, and down.
Inventors: |
Haggquist; Gregory W.;
(Longmont, CO) ; Vinson; Rachel; (Boulder, CO)
; Muldoon; Devin; (Boulder, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cocona, Inc. |
Boulder |
CO |
US |
|
|
Family ID: |
1000004944282 |
Appl. No.: |
16/862457 |
Filed: |
April 29, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62840307 |
Apr 29, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06M 2101/06 20130101;
D06M 13/137 20130101; D06M 13/144 20130101; D06M 15/347 20130101;
D06M 19/00 20130101 |
International
Class: |
D06M 15/347 20060101
D06M015/347; D06M 13/144 20060101 D06M013/144; D06M 13/137 20060101
D06M013/137; D06M 19/00 20060101 D06M019/00 |
Claims
1. A method for attaching an active particle to a substrate, the
method comprising: a. dispersing a plurality of
polymer-chain-coupled particles in a solvent, wherein i. each
polymer-chain-coupled particle comprises at least one polymer chain
and an active particle with a diameter of 0.2 .mu.m-50 .mu.m, and
ii. the solvent relaxes the at least one polymer chain; b. adding a
substrate to the organic solvent to create a mixture, wherein the
substrate comprises a fiber; and c. adding a non-solvent to the
mixture, wherein i. the non-solvent causes the polymer chain to
collapse and mechanically bond to the substrate, and ii. the
mechanical bond is not a chemical bond.
2. The method of claim 1, wherein the active particle has a
porosity of .gtoreq.10 g/m.sup.2 and adsorbs 1%-50% (w/w)
water.
3. The method of claim 1, wherein the active particle is not
soluble in water or dimethylformamide.
4. The method of claim 1, wherein the active particle is a
zeolite.
5. The method of claim 1, wherein the substrate is added to the
solvent at step (c) in an amount that provides a ratio by weight of
1%-10% of polymer-chain-coupled particles to substrate in the
mixture.
6. The method of claim 1, wherein the plurality of
polymer-chain-coupled particles are made by combining the active
particles with the polymer chains at a ratio of 3:1-10:1 by weight,
respectively, wherein the polymer chain binds to the active
particle through an epoxide bond.
7. The method of claim 1, wherein the polymer chains have an
average length that is greater than ten units.
8. The method of claim 7, wherein the polymer chains have an
average molecular weight of 100 Daltons-5,000 Daltons.
9. The method of claim 1, wherein the fiber comprises a natural
fiber selected from the group consisting of cotton, wool, and
down.
10. The method of claim 1, wherein the solvent comprises an
alcohol, and the non-solvent comprises water.
11. A method for making a functional fabric comprising the steps
of: a. combining zeolite particles with activated
polydimethylsiloxane at by-weight ratio 3:1-10:1, respectively, in
a solution containing isopropyl alcohol with a pH of 4-5.5 adjusted
with acetic acid to form polymer-chain-coupled particles; b. drying
the polymer-chain-coupled particles to form a powder; c. combining
the powder with a fabric containing natural fibers in a ratio of
1%-10% (w/w), respectively, in 95% ethanol; d. incubating the
combination of step (c) for 5-30 minutes; e. adding water to the
combination at a volume that is at least 3-times the volume of the
95% ethanol and incubating about 5-30 minutes; f. removing the
ethanol and water from the fabric; and g. drying the fabric.
12. A system comprising a substrate and a plurality of particles,
wherein each of the particles is bonded to a plurality of polymer
chains, and wherein the particles are mechanically bonded to the
substrate by said plurality of polymer chains.
13. The system of claim 12, wherein the particles comprise active
particles.
14. The system of claim 12, wherein the particles comprise
zeolites.
15. The system of claim 12, wherein the particles adsorb between
one and 50 percent by weight of water.
16. The system of claim 12, wherein the particles have a porosity
of greater than 10 g/m.sup.2.
17. The system of claim 12, wherein the particles have an average
particle diameter of between 0.2 and 50 microns, inclusive.
18. The system of claim 12, wherein the particles comprise between
one and ten percent of the weight of the substrate, inclusive.
19. The system of claim 12, wherein the polymer chains are coupled
to the particles using silanes or siloxanes.
20. The system of claim 12, wherein the substrate comprises a
natural fiber.
21. A system comprising a natural fiber and a plurality of active
particles having a porosity of greater than 10 g/m.sup.2, wherein
each of the active particles is bonded to a plurality of polymer
chains using silanes or siloxanes, and wherein the active particles
are mechanically bonded to the natural fiber by said plurality of
polymer chains.
Description
PARENT CASE TEXT
[0001] This application claims priority to U.S. Provisional Patent
Application No. 62/840,307 which was filed on Apr. 29, 2019 and
which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention is related to materials with
performance-enhancing or additive particles. In particular, but not
by way of limitation, the invention is related to mechanically
attaching a performance-enhancing particle to various substrates
including, but not limited to, natural materials such as cotton,
wool, and down.
BACKGROUND OF THE INVENTION
[0003] Performance-enhancing particles have been incorporated into
fabrics using a number of methods. These methods range from
printing on to membranes, to incorporating the particles on the
textiles themselves, to incorporating particles into yarn via a
master batch from which the yarn is created. These
performance-enhancing particles can include adsorbent and absorbent
particles. Descriptions of methods for making and using these
particles, and integrating these particles into fabrics by chemical
bonding, i.e., ionic or covalent bonding, can be found in U.S. Pat.
No. 10,266,986, which is herein incorporated by reference in its
entirety.
[0004] While the state of the art offers methods for making fabrics
with performance-enhancing particles attached by chemical bonds,
there remains a long-felt and unmet need for physicomechanical or
other non-chemical methods for integrating performance-enhancing
particles into fabrics to enable a greater range of substrate fiber
types.
SUMMARY OF THE INVENTION
[0005] Applicant describes herein systems and methods for making
substrates containing performance-enhancing particles (either
absorbent or adsorbent, preferably adsorbent) by incorporating
those particles onto the surface of a substrate using a mechanical
bond. As disclosed herein, those particles can be fixed to one or
more polymer strands to form a polymer-chain-coupled particle
(a.k.a., a particle-polymer strand complex or "hairy particle"),
and those polymer strands are used to attach the particle to the
surface of the substrate. In one embodiment, the
polymer-chain-coupled particle is physically wrapped, aligned, or
otherwise bonded to the substrate (e.g., fabric fiber) without
employing a chemical bond. This is referred to herein as a
physicomechanical bond or a mechanical bond. In futher embodiments,
the polymer-chain-coupled particle may additionally be chemically
bonded to the substrate.
[0006] Aspects and embodiments of the present invention teach
methods, systems, apparatuses, and textiles that mechanically
incorporate particle additives onto the surface of a substrate
using polymer chains. The substrate can be any fiber, feather, or
fabric, and includes natural materials such as cotton, wool, and
down. The particle additives can comprise "active particles," i.e.,
those particles that adsorb materials due to a large surface area
(e.g., activated carbon or zeolites), and can be applied during a
wash and rinse step. The particles can have any suitable size, and
by way of example the size can vary from 100 nm to 50 .mu.m. The
terms "particles," "particle additives," and "performance-enhancing
particle(s)" include but are not limited to "active particle(s)" as
described herein.
[0007] In one aspect, a method for making polymer-chain-coupled
particles, which contain particles and polymers, is provided. In
one embodiment, the particles can be modified chemically to add
polymer chains to the particles. There are several functional
groups that can be used. In one embodiment, the method is to a
family of chemicals termed silane couplers. In another embodiment,
the method is to a family of chemicals termed siloxane couplers.
These couplers have a hydrolyzable group that chemically reacts
with and binds to the particles. The polymer-chain part of the
silane coupler can be greater than 10 units, with longer chains
being preferred. In various embodiments, the silane coupler is
greater than 15 units, greater than 20 units, greater than 25
units, and in further embodiments up to 100,000 units. In these or
other various embodiments, the silane coupler is greater than 15
units, greater than 20 units, greater than 25 units, and in further
embodiments up to 100,000 units.
[0008] In another aspect, a method for attaching
polymer-chain-coupled particles to a substrate is provided. In
various embodiments, attaching polymer-chain-coupled particle
additives to the substrate is accomplished by using an anchoring
group on the polymer-chain-coupled particle. The anchoring group
can have a reactive site that can attach to the substrate. In one
embodiment, the attachment of the polymer-chain-coupled particle to
the substrate is performed in a wash/rinse step. The particles that
have the anchoring group are dispersed in an organic solvent that
causes the polymer chains to expand or relax, such as an alcohol.
The substrate is then added to the dispersion and mixed. The
natural material is partially or fully covered by the dispersion.
After mixing for a predetermined period of time, such as, e.g., 5
to 30 minutes, a non-solvent such as water is added to the
dispersion. This causes the polymer chains to collapse on
themselves and thereby partially or fully wrap around the
substrate, creating a strong mechanical bond between the additive
particles and the substrate.
[0009] In one embodiment, it is desirable to load the
polymer-chain-coupled particles onto the substrate at a ratio of
0.1% w/w to 10% w/w, respectively, depending on the material
application. The performance-enhancing particles can add a number
of enhanced properties to the substrate such as thermoregulation
function, warming function, cooling function, conductivity
function, odor management function, and water vapor diffusion
function to the substrate.
[0010] Further embodiments comprise methods of coupling or
attaching one or more particles to a substrate, such as a fiber,
that can be part of a textile product. In one embodiment, the fiber
comprises a substrate operatively coupled to a particle additive
using long polymer chains.
[0011] In various embodiments, the particle additive can adsorb
between 1% to 50% per weight of water, have a porosity of >15
g/m2, not soluble in water or dimethylformamide, and/or have an
average particle diameter between 1 micron and 20 microns,
inclusive.
[0012] In another aspect, a system, which contains a plurality of
polymer-chain-coupled particles that are mechanically bonded to a
substrate, is provided.
[0013] In one embodiment, the system is produced by (a) dispersing
a plurality of polymer-chain-coupled particles in an organic
solvent to expand the polymer chains of the polymer-chain-coupled
particles, (2) adding a substrate to the organic solvent to create
a mixture, and (3) adding a non-solvent to the mixture to cause the
polymer chains to collapse and mechanically bond to the
substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] 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:
[0015] FIG. 1 depicts polymer-chain-coupled particles. FIG. 1A
depicts a polymer-chain-coupled particle with its polymer chains
110 extended outward from the particle 120. FIG. 1B depicts a
polymer-chain-coupled particle with its polymer chains 110
collapsed.
[0016] FIG. 2 depicts a polymer-chain-coupled particle with its
polymer chains 120 wrapped around a substrate 130.
[0017] FIG. 3 is a flow chart depicting a process for attaching
polymer-chain-coupled particles to a substrate.
DETAILED DESCRIPTION
[0018] Definitions are given to the terms and phrases located
within quotation marks (" ") in the following paragraph. These
definitions are intended to be applied to the terms and phrases
throughout this document, including in the claims, unless clearly
indicated otherwise in context. Further, as applicable, the stated
definitions are to apply, regardless of the word or phrase's case,
tense or any singular or plural variations of the defined word or
phrase.
[0019] The term "or" as used in this specification and the appended
claims is not meant to be exclusive; rather the term is inclusive
meaning "either or both". 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 the embodiment is
included in at least an embodiment of the invention. The
appearances of phrases like "in one embodiment", "in an
embodiment", or "in a variation" in various places in the
specification are not necessarily all meant to refer to the same
embodiment or variation.
Mechanical Coupling of Polymer-Chain-Coupled Particles to a
Substrate
[0020] The invention provides a method for attaching a plurality of
polymer-chain-coupled particles ("PCC particles" or "PCCP") to a
substrate. In a preferred embodiment, the PCCP is attached to the
substrate with mechanical or fictional forces without forming a
chemical bond (ionic or covalent) between the PCCP and
substrate.
[0021] Referring to FIG. 3, in one embodiment, the method of
attachment includes the sequential steps of (1) dispersing the
plurality of polymer-chain-coupled particles in an organic solvent
to expand the polymer chains, (2) adding the substrate to the
organic solvent to create a mixture, and then (3) adding a
non-solvent to the mixture to cause the polymer chains to collapse
and mechanically bond to the substrate.
[0022] In some embodiments, the substrate is a natural fiber or a
synthetic fiber. Preferably, the substrate is a natural fiber. In
some embodiments, the natural fiber contains one or more of is one
or more of cotton, wool, and down.
[0023] In one embodiment, the organic solvent is an alcohol. In one
embodiment, the organic solvent contains one or more of an alkane
hydrocarbon, an alkene hydrocarbon, an alkyne hydrocarbon, an
ether, an aldehyde, an alcohol, and a ketone. In one embodiment,
the organic solvent is an isoamyl alcohol, and isopropyl alcohol,
or an ethyl alcohol. Preferably, the organic solvent is isopropyl
alcohol.
[0024] In one embodiment, the non-solvent comprises water. In one
embodiment, the organic solvent comprises ethyl alcohol and the
non-solvent comprises water.
[0025] In one embodiment, the mixture has a pH of 4-5.5. In one
embodiment, the pH is maintained using a buffer adjusted with an
acid, such as acetate-acetic acid, phosphate buffer saline and
hydrochloric acid, or the like. A preferred acid for maintaining pH
is acetic acid.
[0026] In one embodiment, the mixture is mixed for 5-30 minutes,
5-20 minutes, 5-10 minutes, 5 minutes, 10 minutes, 15 minutes, 20
minute, 25 minutes, 30 minutes, 45 minutes, or 60 minutes.
[0027] In one embodiment, the polymer-chain-coupled particles are
physically contacted to the surface of the substrate at a surface
density of at least 1% by weight (w/w), 1% w/w, 2% w/w, 3% w/w, 4%
w/w, 5% w/w, 10% w/w, 20% w/w, 25% w/w, 30% w/w, 40% w/w, or 50%
w/w.
[0028] In a specific embodiment, the particles are reacted with
polyether amines. The reacted particles (i.e., hairy particles)
have been added to down feathers, a cotton fabric, and/or a wool
fabric. The verification of the addition is done by FTIR and Ash of
the material. Various prototypes include but are not limited by
natural fabrics including Down samples, Cotton fabric and wool
fabric.
[0029] In a specific embodiment, the plurality of
polymer-chain-coupled particles (which collectively form a powder,
a.k.a. powder) is treated with 10% mono-(3-epoxy)propylether
terminated polydimethylsiloxane, asymmetric (hereinafter siloxane
or siloxane polymer) in alcohol set to a pH of 4.0 to 5.5 using
acetic acid. The powder is provided at 10% w/w of the cocoon
natural fiber used. In a specific embodiment, the components of the
mixture are 1.0 g siloxane polymer, 10.0 g polymer-chain-coupled
particle powder, 100.0 g isopropyl alcohol, and acetic acid to pH
5. Table 1 shows the modified particles of Down and Fabric
samples.
TABLE-US-00001 TABLE 1 Modified Particles Down and Fabric Samples
Summary PPM Base % Ash Powder Material Isopropyl Water (Calculation
Material Trial Residual FTIR Applied (g) Treated (g) Alcohol (mL).
(mL) From Ash) Down Blank 0.83 No 0.0000 1.5000 0 0 -- Down 1 2.82
Yes 0.0200 1.1916 200 50 16,700 Down 2 1.53 Yes 0.0365 1.2636 200
50 5,540 Down 3 6.91 Yes 0.1549 1.5086 200 50 40,302 Cotton Blank
0.42 No 0.0000 1.5000 0 0 -- Cotton 2 0.68 Yes 0.0740 1.4800 75 225
1,757
[0030] Table 2 provides the powder production.
TABLE-US-00002 TABLE 2 Powder Production Batch Powder (g) Silane
(g) Isopropyl Alcohol (g) 1 10 1 100 2 30 3 300 3 20 2 200 4 40 4
400 5 50 5 500 6 20 2 200 7 50 5 500 8 50 5 500
Polymer-Chain-Coupled Particles
[0031] Referring to FIG. 1, in one embodiment, each of the
polymer-chain-coupled particles comprise a particle 120 and one or
more polymer chains 110. In one embodiment, each of the
polymer-chain-coupled particles consist essentially of a particle
120 and one or more polymer chains 110. Preferably, the particle
120 is a performance-enhancing particle such as an active particle,
meaning that it can facilitate the movement of material, such as,
e.g., water, from a proximal area to a distal area. For example, in
those embodiments in which the particle is integrated into a fabric
that is worn against a body, the active particles facilitate the
movement of material, e.g., water, from the inner surface of the
fabric (i.e., the proximal area) to the outer surface of the fabric
(i.e., the distal surface). Here, the active particle contains
pores that provide a very large surface area for adsorption and
eventual movement of materials across the axis of the particle.
[0032] In one embodiment, the particles are not soluble in water or
dimethylformamide. In one embodiment, the particles are not soluble
in water. In one embodiment, the particles are not soluble in
dimethylformamide.
[0033] In one embodiment, the particles adsorb 1%-50% by weight of
water, .gtoreq.50% by weight of water, 50%-100% by weight of water,
10%-20% by weight of water, 15%-25% by weight of water, 20%-30% by
weight of water, 25%-35% by weight of water, 30%-40% by weight of
water, 35%-45% by weight of water, 40%-50% by weight of water,
45%-55% by weight of water, 50%-60% by weight of water, 55%-65% by
weight of water, 60%-70% by weight of water, 65%-75% by weight of
water, 70%-80% by weight of water, 75%-85% by weight of water,
80%-90% by weight of water, 85%-90% by weight of water, 90%-100% by
weight of water, or 95%-105% by weight of water.
[0034] In one embodiment, the particles have a porosity of greater
than 10 g/m.sup.2, greater than 20 g/m.sup.2, greater than 30
g/m.sup.2, 10 g/m.sup.2-20 g/m.sup.2, 15 g/m.sup.2-25 g/m.sup.2, 20
g/m.sup.2-30 g/m.sup.2, 25 g/m.sup.2-35 g/m.sup.2, 30 g/m.sup.2-40
g/m.sup.2, 35 g/m.sup.2-45 g/m.sup.2, 40 g/m.sup.2-50 g/m.sup.2, 45
g/m.sup.2-55 g/m.sup.2, 50 g/m.sup.2-60 g/m.sup.2, 55 g/m.sup.2-65
g/m.sup.2, greater than 60 g/m.sup.2, 10 g/m.sup.2-100 g/m.sup.2,
10 g/m.sup.2-75 g/m.sup.2, or 15 g/m.sup.2-80 g/m.sup.2.
[0035] In one embodiment, the particles 120 have an average
particle diameter
[0036] In one embodiment, the particles have an average particle
diameter of 0.2-50 microns, 0.2-40 microns, 0.2-30 microns, 0.2-20
microns, 0.2-10 microns, 0.2-5 microns, 0.2-1 microns, 1-25
microns, 0.1 microns, 0.5 microns, 1 micron, 5 microns, 10 microns,
15 microns, 20 microns, 25 microns, 30 microns, 35 microns, 40
microns, 45 microns, or 50 microns.
[0037] In one embodiment, the particles comprise 1%-5%, no more
than 10%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 9% the weight of
the substrate.
[0038] In a specific embodiment, the particles comprise
zeolites.
[0039] In one embodiment, the plurality of polymer-chain-coupled
particles are in powdered form.
The Polymer Chains
[0040] In one embodiment, the plurality of polymer-chain-coupled
particles comprise an average of at least a one-to-one (1:1)
particle-to-polymer mass ratio to no more than a twenty-to-one
(20:1) particle-to-polymer mass ratio, .ltoreq.10:1, 2:1, 3:1, 4:1,
5:1, 6:1, 7:1, 8:1, 9:1, 10:1, 11:1, 12:1, 13:1, 14:1, 15:1, 16:1,
17:1, 18:1, 19:1, or 20:1 particle-to-polymer mass ratio.
[0041] In one embodiment, the polymer chains have an average length
that is 10 units, 11 units, 12 units, 13 units, 14 units, 15 units,
16 units, 17 units, 18 units, 19 units, 20 units, 21 units, 22
units, 23 units, 24 units, 25 units, or more than 25 units. In one
embodiment, the polymer has a molecular weight of .gtoreq.100
Daltons, 100-5,000 Daltons, 100 Daltons, 250 Daltons, 500 Daltons,
600 Daltons, 700 Dalton, 1,000 Daltons, 2,000 Daltons, 3,350
Daltons, or 5,000 Daltons.
[0042] In one embodiment, the polymer chains are coupled to the
particles using silanes or siloxanes.
[0043] Tables 3 and 4 describe embodiments of polymer length
relative to fiber circumference.
TABLE-US-00003 TABLE 3 Polymer Length versus Substrate Fiber
Circumference (all units are in microns) Siloxane Polymer 0.011718
length Percent ratio Diameter Circumference polymer/circumference
Wool 11.5 24 36.13 75.40 0.032% Cotton 11 22 34.56 69.12 0.034%
Down 2 6 6.28 18.85 0.186%
TABLE-US-00004 TABLE 4 Polymer Length versus Substrate Fiber
Circumference (all units are in microns unless indicated otherwise)
Si--O n= 6300 units .times. 1.64 angstroms per unit C-C n= 9 units
.times. 1.54 angstroms per unit Polymer length 1.034586 microns
Percent ratio Diameter Circumference polymer/circumference Wool
11.5 24 36.13 75.40 2.864% Cotton 11 22 34.56 69.12 2.994% Down 2 6
6.28 18.85 16.446%
[0044] Turning now to FIG. 1, seen is one embodiment of the
polymer-chain-coupled particle (a "hairy particle"), wherein an
active particle is combined with a silane coupling agent. Active
particles are particles that have pores or traps that have the
capacity to adsorb and desorb substances in solid, liquid, and/or
gas phases, and/or combinations thereof. These pores can vary in
size, shape, and quantity, depending on the type of active particle
that is being used. For example, some active particles naturally
have pores, such as volcanic rock, and other particles such as
carbon may be treated with extreme temperature and an activating
agent such as oxygen to create the pores, e.g., as in biochar.
[0045] Active particles can provide performance enhancing
properties to the item they are included within. Such performance
enhancing properties include odor adsorption, moisture management,
humidity capture and release, ultraviolet light protection,
infrared absorbance, chemical agent protective properties,
bio-hazard protective properties, fire retardance, antibacterial
protective properties, antiviral protective properties, antifungal
protective properties, antimicrobial protective properties,
desiccant properties, and combinations thereof. Active particles
can include, but are not limited to, activated carbon and
zeolites.
[0046] In one embodiment, the material may comprise an
end-functional long chain group and may be referred to herein as a
long-chain group, a functional group, a reactive group, an amine
group, an anchor, or an anchoring group. Other material types
comprise long-chain groups related to one or more of a cellulose,
polyester, polyvinyl alcohol, polystyrene, polyacrylic,
polypropylene, polyurethane (aliphatic and aromatic), aramids, and
polyamide.
[0047] The substrate may comprise a natural fiber. Substrates can
include, but are not limited to polyester, polyamide, aramids
(Kevlar.RTM. and Nomex.RTM.), cottons, wools, Down, polyurethanes,
modified acrylics, polyacrylics, rayons, polypropylenes, and other
textile fibers. In one embodiment, the material is a natural
material including, but not limited to down, wool, and/or
cotton.
[0048] Deactivation of active particles occurs when a material is
coupled to the pores and/or other surface areas of the active
particles and blocks their ability to adsorb and desorb a
substance. Active particles are particles that comprise pores or
other surface area features which can adsorb and desorb a
substance. Active particles can exist in a deactivated state when
the pores and/or the surface area of active particles are blocked
or inhibited from adsorbing a substance of certain molecular size.
However, this does not always mean that these pores/surface areas
are permanently precluded from adsorbing that substance. The
pores/surface area of the active particles can be unblocked or
uninhibited (i.e., generally or substantially returned to their
original state) through reactivation or rejuvenation. Reactivation
or rejuvenation removes substances that are trapped in the pores of
the active particles, blocking their activity. However, if a
deleterious substance is adsorbed by the active particles, it is
unlikely that reactivation or rejuvenation can restore the
adsorptive capacity of the active particles.
[0049] As described previously, the material may comprise one or
more long chain groups.
EMBODIMENTS
[0050] A first embodiment provides a method for attaching a
plurality of polymer-chain-coupled particles to a substrate
comprising the steps of (a) dispersing the plurality of
polymer-chain-coupled particles in an organic solvent to expand the
polymer chains of the polymer-chain-coupled particles, (2) adding a
substrate to the organic solvent to create a mixture, and (3)
adding a non-solvent to the mixture to cause the polymer chains to
collapse and mechanically bond to the substrate.
[0051] A second embodiment provides a method of the first
embodiment, wherein the particles of the polymer-chain-coupled
particles comprise active particles.
[0052] A third embodiment provides a method of the first embodiment
or the second embodiment, wherein the particles adsorb between one
and 50 percent by weight of water.
[0053] A fourth embodiment provides a method of any one of the
first through third embodiments, wherein the particles have a
porosity of greater than 10 g/m2.
[0054] A fifth embodiment provides a method of any one of the first
through fourth embodiments, wherein the particles are not soluble
in water or dimethylformamide.
[0055] A sixth embodiment provides a method of any one of the first
through fifth embodiments, wherein the particles have an average
particle diameter of between 0.2 and 50 microns, inclusive.
[0056] A seventh embodiment provides a method of any one of the
first through sixth embodiments, wherein the particles comprise
1%-5%, or as high as 10% of the weight of the substrate,
inclusive.
[0057] An eighth embodiment provides a method of any one of the
first through seventh embodiments, wherein the particles comprise
zeolites.
[0058] A ninth embodiment provides a method of any one of the first
through eighth embodiments, wherein the polymer-chain-coupled
particles are physically contacted to the surface of the substrate
at a surface density of at least one percent by weight.
[0059] A tenth embodiment provides a method of any one of the first
through ninth embodiments, wherein the plurality of
polymer-chain-coupled particles comprise an average of at least a
one-to-one (1:1) particle-to-polymer mass ratio to no more than a
twenty-to-one (20:1) particle-to-polymer mass ratio.
[0060] An eleventh embodiment provides a method of any one of the
first through tenth embodiments, wherein the plurality of
polymer-chain-coupled particles comprise an average of no more than
a ten-to-one (10:1) particle-to-polymer mass ratio.
[0061] A twelfth embodiment provides a method of any one of the
first through eleventh embodiments, wherein the plurality of
polymer-chain-coupled particles comprise a three-to-one (3:1)
particle-to-polymer mass ratio.
[0062] A thirteenth embodiment provides a method of any one of the
first through twelfth embodiments, wherein the plurality of
polymer-chain-coupled particles are in powdered form.
[0063] A fourteenth embodiment provides a method of any one of the
first through thirteenth embodiments, wherein the polymer chains
are coupled to the particles using silanes or siloxanes to form the
polymer-chain-coupled particles.
[0064] A fifteenth embodiment provides a method of any one of the
first through fourteenth embodiments, wherein the polymer chains
have an average length that is greater than ten units.
[0065] A sixteenth embodiment provides a method of any one of the
first through fifteenth embodiments, wherein the polymer chains
have an average length that is greater than 25 units.
[0066] A seventeenth embodiment provides a method of any one of the
first through sixteenth embodiments, wherein the polymer chains
have an average molecular weight between 100 Daltons and 5,000
Daltons, inclusive.
[0067] An eighteenth embodiment provides a method of any one of the
first through seventeenth embodiments, wherein the polymer chains
have an average length that is 0.01%-16.5% of the circumference of
the substrate.
[0068] A nineteenth embodiment provides a method of any one of the
first through eighteenth embodiments, wherein the polymer chains
have an average length that is 0.032%-0.186% of the circumference
of the substrate.
[0069] A twentieth embodiment provides a method of any one of the
first through nineteenth embodiments, wherein the substrate
comprises a natural fiber.
[0070] A twenty-first embodiment provides a method of any one of
the first through twentieth embodiments, wherein the substrate
comprises a natural fiber that is at least one of cotton, wool, and
down.
[0071] A twenty-second embodiment provides a method of any one of
the first through twenty-first embodiments, wherein the organic
solvent comprises alcohol.
[0072] A twenty-third embodiment provides a method of any one of
the first through twenty-second embodiments, wherein the
non-solvent comprises water.
[0073] A twenty-fourth embodiment provides a method of any one of
the first through twenty-third embodiments, wherein the mixture has
a pH 4-5.5, inclusive.
[0074] A twenty-fifth embodiment provides a method of any one of
the first through twenty-fourth embodiments, wherein the mixture
has a pH that is maintained using an acid.
[0075] A twenty-sixth embodiment provides a method of any one of
the first through twenty-fifth embodiments further comprising
mixing the mixture.
[0076] A twenty-seventh embodiment provides a method of any one of
the first through twenty-sixth embodiments comprising mixing the
mixture for five to thirty minutes.
[0077] A twenty-eighth embodiment provides a system comprising a
plurality of polymer-chain-coupled particles mechanically bonded to
a substrate, wherein each polymer-chain-coupled particle of the
plurality of polymer-chain-coupled particles comprises one or more
particles and one or more polymers.
[0078] A twenty-ninth embodiment provides a system of the
twenty-eighth embodiment, wherein the plurality of
polymer-chain-coupled particles are mechanically bonded to the
substrate by (a) dispersing the plurality of polymer-chain-coupled
particles in an organic solvent to expand the polymer chains of the
polymer-chain-coupled particles, (2) adding a substrate to the
organic solvent to create a mixture, and (3) adding a non-solvent
to the mixture to cause the polymer chains to collapse and
mechanically bond to the substrate.
[0079] A thirtieth embodiment provides a system of the
twenty-eighth or twenty-ninth embodiment, wherein the particles of
the polymer-chain-coupled particles comprise active particles.
[0080] A thirty-first embodiment provides a system of any one of
the twenty-eighth through thirtieth embodiments, wherein the
particles adsorb between one and 50 percent by weight of water.
[0081] A thirty-second embodiment provides a system of any one of
the twenty-eighth through thirty-first embodiments, wherein the
particles have a porosity of greater than 10 g/m2.
[0082] A thirty-third embodiment provides a system of any one of
the twenty-eighth through thirty-second embodiments, wherein the
particles are not soluble in water or dimethylformamide.
[0083] A thirty-fourth embodiment provides a system of any one of
the twenty-eighth through thirty-third embodiments, wherein the
particles have an average particle diameter of between 0.2 and 50
microns, inclusive.
[0084] A thirty-fifth embodiment provides a system of any one of
the twenty-eighth through thirty-fourth embodiments, wherein the
particles comprise 1%-5%, or as high as 10% of the weight of the
substrate, inclusive.
[0085] A thirty-sixth embodiment provides a system of any one of
the twenty-eighth through thirty-fifth embodiments, wherein the
particles comprise zeolites.
[0086] A thirty-seventh embodiment provides a system of any one of
the twenty-eighth through thirty-sixth embodiments, wherein the
polymer-chain-coupled particles are physically contacted to the
surface of the substrate at a surface density of at least one
percent by weight.
[0087] A thirty-eighth embodiment provides a system of any one of
the twenty-eighth through thirty-seventh embodiments, wherein the
plurality of polymer-chain-coupled particles comprise an average of
at least a one-to-one (1:1) particle-to-polymer mass ratio to no
more than a twenty-to-one (20:1) particle-to-polymer mass
ratio.
[0088] A thirty-ninth embodiment provides a system of any one of
the twenty-eighth through thirty-eighth embodiments, wherein the
plurality of polymer-chain-coupled particles comprise an average of
no more than a ten-to-one (10:1) particle-to-polymer mass
ratio.
[0089] A fortieth embodiment provides a system of any one of the
twenty-eighth through thirty-ninth embodiments, wherein the
plurality of polymer-chain-coupled particles comprise a
three-to-one (3:1) particle-to-polymer mass ratio.
[0090] A forty-first embodiment provides a system of any one of the
twenty-eighth through fortieth embodiments, wherein the plurality
of polymer-chain-coupled particles are in powdered form.
[0091] A forty-second embodiment provides a system of any one of
the twenty-eighth through forty-first embodiments, wherein the
polymer chains are coupled to the particles with silanes or
siloxanes to form the polymer-chain-coupled particles.
[0092] A forty-third embodiment provides a system of any one of the
twenty-eighth through forty-second embodiments, wherein the polymer
chains have an average length that is greater than ten units.
[0093] A forty-fourth embodiment provides a system of any one of
the twenty-eighth through forty-third embodiments, wherein the
polymer chains have an average length that is greater than 25
units.
[0094] A forty-fifth embodiment provides a system of any one of the
twenty-eighth through forty-fourth embodiments, wherein the polymer
chains have an average molecular weight between 100 Daltons and
5,000 Daltons, inclusive.
[0095] A forty-sixth embodiment provides a system of any one of the
twenty-eighth through forty-fifth embodiments, wherein the polymer
chains have an average length that is 0.01%-16.5% of the
circumference of the substrate.
[0096] A forty-seventh embodiment provides a system of any one of
the twenty-eighth through forty-sixth embodiments, wherein the
polymer chains have an average length that is 0.032%-0.186% of the
circumference of the substrate.
[0097] A forty-eighth embodiment provides a system of any one of
the twenty-eighth through forty-seventh embodiments, wherein the
substrate comprises a natural fiber.
[0098] A forty-ninth embodiment provides a system of any one of the
twenty-eighth through forty-eighth embodiments, wherein the
substrate comprises a natural fiber that is at least one of cotton,
wool, and down.
[0099] A fiftieth embodiment provides a system of any one of the
twenty-ninth through forty-ninth embodiments, wherein the organic
solvent comprises alcohol.
[0100] A fifty-first embodiment provides a system of any one of the
twenty-ninth through fiftieth embodiments, wherein the non-solvent
comprises water.
[0101] A fifty-second embodiment provides a system of any one of
the twenty-ninth through fifty-first embodiments, wherein the
mixture has a pH 4-5.5, inclusive.
[0102] A fifty-third embodiment provides a system of any one of the
twenty-ninth through fifty-second embodiments, wherein the mixture
has a pH that is maintained using an acid.
[0103] A fifty-fourth embodiment provides a system of any one of
the twenty-ninth through fifty-third embodiments, wherein the
mixture is formed by mixing the mixture for five to thirty
minutes.
[0104] A fifty-fifth embodiment provides a method for making a
functional fabric comprising the steps of (1) combining zeolite
particles with activated polydimethylsiloxane at by-weight ratio
3:1-10:1, respectively, in a solution containing isopropyl alcohol
with a pH of 4-5.5 adjusted with acetic acid to form
polymer-chain-coupled particles, (2) drying the
polymer-chain-coupled particles to form a powder, (3) combining the
powder with a fabric containing natural fibers in a ratio of 1%-10%
(w/w), respectively, in 95% ethanol, (4) incubating the combination
of step (c) for 5-30 minutes, (5) adding water to the combination
at a volume that is at least 3-times the volume of the 95% ethanol
and incubating about 5-30 minutes, (6) removing the ethanol and
water from the fabric; and (7) drying the fabric.
[0105] A fifty-sixth embodiment provides a functional fabric
produced by the method of the fifty-fifth embodiment.
[0106] A fifty-seventh embodiment provides a system that contains a
natural fiber and a plurality of active particles having a porosity
of greater than 10 g/m.sup.2, in which each of the active particles
is bonded to a plurality of polymer chains using silanes or
siloxanes, and wherein the active particles are mechanically
bonded, but not chemically bonded, to the natural fiber by said
plurality of polymer chains. By not chemically bonded, What is
meant by "not chemically bonded" is that no ionic or covalent bonds
are formed between the natural fiber and the active particles or
the polymer chains.
[0107] Those skilled in the art can readily recognize that numerous
variations and substitutions may be made in the invention, its use
and its configuration to achieve substantially the same results as
achieved by the embodiments described herein. Accordingly, there is
no intention to limit the invention to the disclosed exemplary
forms. Many variations, modifications and alternative constructions
fall within the scope and spirit of the disclosed invention as
expressed in the claims. The Examples are not meant to limit the
scope of the invention.
EXAMPLES
Example 1: Modification of Powder to Produce Polymer-Chain-Coupled
Particles
[0108] Materials used included: powdered performance-enhancing
particles ("PP-EP", 37.5 powder, lot: 12-10);
mono-(2,3-epoxy)propylether terminated polydimethyl-siloxane,
asymmetric ("PDMS polymer" or "silane") (MCR-E21, Gelest,
Morrisville, Pa.); 91% isopropyl alcohol (IPA), and acetic
acid.
[0109] The process for chemically binding the performance-enhancing
particles to PDMS polymer to produce polymer-chain-coupled
particles included the steps of: measuring out the powder,
measuring out the alcohol, adjusting pH of alcohol to 4.5-5.5 with
acetic acid, adding silane to alcohol, mixing, adding the resultant
solution to the powdered performance-enhancing particles, and
stirring well for one hour. After stirring well for one hour, the
alcohol was decanted, the powder dried, and the complex was placed
in an oven at 110.degree. C. for about 20 minutes.
[0110] Various batch sizes that were generated and tested are
tabulated in table 5.
TABLE-US-00005 TABLE 5 Test Batches (all amounts are in grams; pH
is in pH units) Batch 1 2 3 4 5 6 7 8 PP-EP 10 30 20 40 50 20 50 50
(powder) Silane 1 3 2 4 5 2 5 5 (PDMS) IPA (alcohol) 100 300 200
400 500 200 500 500 pH (acetic 5.2 4.5 5.0 5.5 5.3 5.5 5.0 5.1
acid)
Example 2: Fabric Treatment
[0111] Materials used included: 100% cotton fabric; powdered
polymer-chain-coupled particles; and ethanol (95%).
[0112] The process for mechanically bonding the
polymer-chain-coupled particles ("P-C-C-P" s) to fabric substrates
included the steps of: performing Fourier-transform infrared
spectroscopy (FTIR) on the fabric; cutting uniform swatches of
fabric (approximately 4''.times.4''); and treating the fabric at
three treatment levels (1%, 3%, and 5% of fabric weight, see Tables
6 and 7). Each treating step was performed in a glass tray filled
with enough ethanol to cover the swatch (the volume of ethanol was
recorded). The treating steps were: adding the appropriate amount
of ethanol to the tray; adding the appropriate amount of
polymer-chain-coupled particle powder mix (see Table 6 for example
specimens); adding the swatch to the tray; coating the swatch;
turning the swatch; letting the swatch sit for about 10 minutes;
adding distilled water to the tray in a volume that is three-times
the volume of the ethanol in the tray; letting the swatch sit for
30 minutes in the mixture; draining off the liquid; drying the
swatch (the sample) in an oven; and then testing the treated fabric
sample by FTIR. Table 7 tabulates the several treatment
examples.
TABLE-US-00006 TABLE 6 Exemplar Specimens Specimen Number 1 (1%) 2
(3%) 3 (5%) Fabric (g) 1.46 1.49 1.49 Powdered P-C-C-P (g) 0.0153
0.0449 0.0740 Ethanol (mL) 75 75 50 Water (mL) 225 225 150
TABLE-US-00007 TABLE 7 Treatment Regimens Treatment 1 (at 5%)
Specimen Number 1 2 3 Fabric (g) 1.48 1.48 1.48 Powdered P-C-C-P
(g) 0.074 0.074 0.073 Ethanol (mL) 75 75 75 Water (mL) 225 225 225
Treatment 2 (at 3%) Specimen Number 1 2 3 Fabric (g) 1.51 1.52 1.55
Powdered P-C-C-P (g) 0.0453 0.0457 0.0476 Ethanol (mL) 75 75 75
Water (mL) 225 225 225 Treatment 3 (at 5%) Specimen Number 1 2 3
Fabric (g) 0.3883 0.3940 0.3797 Powdered P-C-C-P (g) 0.0194 0.0195
0.0184 Ethanol (mL) 5 5 5 Water (mL) 15 15 15 Treatment 4 (at 1%)
Specimen Number 1 2 Fabric (g) 1.489 1.506 Powdered P-C-C-P (g)
0.0149 0.0152 Ethanol (mL) 75 75 Water (mL) 225 225
Example 3: Down Treatment Method
[0113] Down was treated according to the following sequential steps
to prepare a product having a 10% ratio of polymer-chain-coupled
particle to down substrate: 1.5086 g of down was weighed into a jar
with a lid (the size of the jar determined the amount of down); an
amount of powdered polymer-chain-coupled particles equal to 10.26%
of the mass of the down (i.e., 0.1549 g particles) was weighed into
a separate beaker; 100 mL of isopropyl alcohol was added to the
beaker containing the particles and mixed at room temperature and
verified by IR gun; the isopropyl alcohol/particle mixture was
added to the down mixture in the jar with the lid; particles that
remained in the beaker were scraped out using a plastic stir stick;
an additional 100 mL of isopropyl alcohol was added to the beaker
to rinse out the left-over particles; the rinse was added to the
down/isopropyl alcohol jar mixture; the jar was closed and shaken
for thirty minutes to ensure uniform distribution of the particles
within the down; the down/isopropyl alcohol mixture was added to a
beaker; 25% of distilled water was slowly added to the beaker
containing the down/isopropyl alcohol mixture (i.e., 50 mL of
distilled water was used); the resultant mixture was stirred for
five minutes; after stirring, the mixture was poured over a metal
screen sifter to remove all of the liquid; return the screened down
mixture was returned to the beaker and rinsed three times with 50
mL of distilled water with draining in between each rinse; and then
the down mixture was put into a 120.degree. C. oven overnight.
[0114] Other down formulations were produced using the same process
as above, but with different weight ratios of polymer-chain-coupled
particles to fiber substrate. One percent and three percent
formulations were produced.
* * * * *