U.S. patent application number 16/991612 was filed with the patent office on 2021-02-18 for eco-friendly polyester fibers and microfiber shed-resistance polyester textiles.
The applicant listed for this patent is Universal Fibers, Inc.. Invention is credited to Richard Marcus Ammen, Ryan Matthew Besch, Stuart P Fairgrieve, Brendan F McSheehy, JR..
Application Number | 20210047756 16/991612 |
Document ID | / |
Family ID | 1000005060677 |
Filed Date | 2021-02-18 |
United States Patent
Application |
20210047756 |
Kind Code |
A1 |
Ammen; Richard Marcus ; et
al. |
February 18, 2021 |
ECO-FRIENDLY POLYESTER FIBERS AND MICROFIBER SHED-RESISTANCE
POLYESTER TEXTILES
Abstract
The present application is generally concerned with
polyester-based fibers, which exhibit enhanced resistance to
breakage and attritional wear. More particularly, the inventive
fibers may be especially aimed at textile applications, wherein the
inventive fibers may reduce the propensity of the textile materials
to produce microplastic and nanoplastic particles during use and
during laundering or other cleaning operations, which are a known
pollution hazard in the natural environment.
Inventors: |
Ammen; Richard Marcus;
(Johnson City, TN) ; Fairgrieve; Stuart P;
(Oxfordshire, GB) ; McSheehy, JR.; Brendan F;
(Abingdon, VA) ; Besch; Ryan Matthew; (Johnson
City, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Universal Fibers, Inc. |
Bristol |
VA |
US |
|
|
Family ID: |
1000005060677 |
Appl. No.: |
16/991612 |
Filed: |
August 12, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62885536 |
Aug 12, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D01F 6/62 20130101; D01F
6/84 20130101; D10B 2331/04 20130101; D01F 1/10 20130101; D04B
21/207 20130101; D04B 1/26 20130101; D01D 5/08 20130101; D01F 8/14
20130101; D10B 2501/021 20130101 |
International
Class: |
D01F 8/14 20060101
D01F008/14; D01F 1/10 20060101 D01F001/10; D04B 1/26 20060101
D04B001/26; D01D 5/08 20060101 D01D005/08; D04B 21/20 20060101
D04B021/20; D01F 6/62 20060101 D01F006/62; D01F 6/84 20060101
D01F006/84 |
Claims
1. A melt-spun polyester fiber for reducing microplastics
pollution, wherein said melt-spun polyester fiber is in the form
of: (i) a core-sheath bicomponent polyester fiber comprising a core
domain and a sheath domain, wherein said core domain comprises a
poly(alkylene terephthalate) and said sheath domain comprises a
homopolyester or copolyester and at least one shed-resistance
additive; or (ii) a monocomponent polyester fiber comprising a
poly(alkylene terephthalate), wherein said monocomponent polyester
fiber is at least partially coated with a shed-resistance
coating.
2. The melt-spun polyester fiber according to claim 1, wherein said
poly(alkylene terephthalate) comprises poly(1,2-ethylene
terephthalate), poly(1,3-propylene terephthalate), or
poly(1,4-butylene terephthalate), and wherein said homopolyester or
said copolyester comprises poly(1,2-ethylene terephthalate),
poly(1,3-propylene terephthalate), or poly(1,4-butylene
terephthalate).
3. The melt-spun polyester fiber according to claim 2, wherein said
melt-spun polyester fiber is said core-sheath bicomponent polyester
fiber.
4. The melt-spun polyester fiber according to claim 3, wherein said
sheath domain comprises an inner layer and an outer layer.
5. The melt-spun polyester fiber according to claim 4, wherein said
inner layer and said outer layer are formed from different
polyesters.
6. The melt-spun polyester fiber according to claim 3, wherein said
melt-spun polyester fiber comprises 0.1 to 25 weight percent of
said shed-resistance additives.
7. The melt-spun polyester fiber according to claim 6, wherein said
shed-resistance additives comprise a lubricant, an impact modifier,
a crosslinker, a chain extender, a crystallization modifier, or
combinations thereof.
8. The melt-spun polyester fiber according to claim 1, wherein said
melt-spun polyester fiber is said monocomponent polyester
fiber.
9. The melt-spun polyester fiber according to claim 8, wherein said
melt-spun polyester fiber comprises 0.1 to 25 weight percent of
said shed-resistance coating, wherein said shed-resistance coating
comprises one or more shed-resistance additives.
10. The melt-spun polyester fiber according to claim 9, wherein
said shed-resistance additives comprise a lubricant, an impact
modifier, a crosslinker, a chain extender, a crystallization
modifier, or combinations thereof.
11. The melt-spun polyester fiber according to claim 1, wherein
said melt-spun polyester fiber exhibits a fiber weight loss after a
washing cycle of less than 2 weight percent.
12. The melt-spun polyester fiber according to claim 1, wherein
said melt-spun polyester fiber exhibits a waste microfibers loss
per gram of tested sample after a washing cycle of less than 10 mg
of waste microfibers.
13. A textile comprising said melt-spun polyester fiber according
to claim 1.
14. An article of manufacture comprising said melt-spun polyester
fiber according to claim 1.
15. A method for forming said melt-spun polyester fiber according
to claim 1, said method comprising melt spinning said poly(alkylene
terephthalate) to thereby form said melt-spun polyester fiber.
16. A melt-spun polyester fiber for reducing microplastics
pollution, wherein said melt-spun polyester fiber is in the form
of: (i) a first core-sheath bicomponent polyester fiber comprising
a first core domain and a first sheath domain, wherein said first
core domain comprises a poly(alkylene terephthalate) and said first
sheath domain comprises a homopolyester or a copolyester that is
different from said fiber-forming poly(alkylene terephthalate);
(ii) a second core-sheath bicomponent polyester fiber comprising a
second core domain and a second sheath domain, wherein said second
core domain comprises a poly(alkylene terephthalate) and said
second sheath domain comprises a homopolyester or a copolyester and
at least one shed-resistance additive; or (iii) a monocomponent
polyester fiber comprising a poly(alkylene terephthalate), wherein
said monocomponent polyester fiber is at least partially coated
with a shed-resistance coating, wherein said melt-spun polyester
fiber exhibits a fiber weight loss after a washing cycle of less
than 2 weight percent, and wherein said melt-spun polyester fiber
exhibits a waste microfibers loss per gram of tested sample after a
washing cycle of less than 10 mg of waste microfibers.
17. The melt-spun polyester fiber according to claim 16, wherein
said poly(alkylene terephthalate) comprises poly(1,2-ethylene
terephthalate), poly(1,3-propylene terephthalate), or
poly(1,4-butylene terephthalate), and wherein said homopolyester or
said copolyester comprises poly(1,2-ethylene terephthalate),
poly(1,3-propylene terephthalate), or poly(1,4-butylene
terephthalate).
18. A textile comprising said melt-spun polyester fiber according
to claim 16.
19. An article of manufacture comprising said melt-spun polyester
fiber according to claim 16.
20. A method for forming said melt-spun polyester fiber according
to claim 16, said method comprising melt spinning said
poly(alkylene terephthalate) to thereby form said melt-spun
polyester fiber.
Description
RELATED APPLICATIONS
[0001] This application claims the priority benefit under 35 U.S.C.
.sctn. 119(e) of U.S. Provisional Patent Application Ser. No.
62/885,536 entitled "ECO-FRIENDLY POLYESTER FIBERS AND MICROFIBER
SHED-RESISTANCE POLYESTER TEXTILES," filed Aug. 12, 2019, the
entire disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field of the Invention
[0002] The present invention is generally concerned with
polyester-based fibers, which exhibit enhanced resistance to
breakage and attritional wear. More particularly, the inventive
fibers may be especially aimed at textile applications, wherein the
inventive fibers may reduce the propensity of the textile materials
to produce microplastic and nanoplastic particles during formation,
use and during laundering or other cleaning operations, which are a
known pollution hazard in the natural environment.
2. Description of the Related Art
[0003] The presence of visible plastics waste in the natural
environment has been noted for many years, indeed almost since such
materials first entered widespread use. While initially a nuisance,
such pollution, especially in the marine environment, has grown to
be a major concern. Large accumulations of pristine or damaged
plastics-based products ("macroplastics"), such as packaging,
fishing gear, and apparel, have been observed both in the open
ocean and on beaches, often in remote locations far from likely
sources of such materials.
[0004] More recently, there has been increasing concern regarding
the presence of smaller size plastics pollution, commonly referred
to as microplastics (i.e., plastics having a particle size of about
100 nm to about 5 mm) and nanoplastics (i.e., plastics having a
particle size of about 100 nm or less), both of which may be
generally classified as "microplastics." Despite being largely
invisible to the naked eye, many experts have expressed concern
that such microplastics pollution could have a range of deleterious
effects on the planetary ecosystem and food chains.
[0005] Initially, it was deduced that microplastics pollution was
derived from two main sources: (1) primary microplastics and (2)
secondary microplastics. Generally, primary microplastics refer to
low particle size polymer particles deliberately produced for
specific purposes. Potential sources of pollution of this type may
include, for example, industrial waste from factories producing low
particle size forms of polymers (e.g., in the form of emulsions or
suspensions); particles used in cosmetic applications, such as skin
exfoliants and dental products; abrasives preparations used in
high-pressure cleaning formulations for the likes of buildings,
roadways, and ships; and, more recently, very low particle size
polymers used in 3D printing inks and in drug delivery systems.
Alternatively, secondary microplastics generally refer to small
particles produced by the physical and/or chemical degradation of
macroplastics already present in the environment.
[0006] Within the last decade or so, compelling evidence has been
found that a major source of microplastics pollution, especially in
the marine, riparian, and littoral environments, is polymeric
microfibers. Such microfibers appear to be mainly derived from
commercial and domestic laundering, or other cleaning processes,
carried out on textiles, in the form of apparel, bedding, soft
furnishings, carpets, etc. Thus, a third source of microplastics
pollution may include microfibers, which generally refers to small
polymer particles derived predominantly from commercial or domestic
laundering or cleaning of textiles and other fibrous products. Such
pollution can be carried into the marine environment via untreated
wastewater; from waste-water treatment plants, whose filters may be
inadequate for trapping such small particles; and via rainwater
run-off carrying microfibers deposited, by filtrate compost or
whatever means, from the land environment. The microplastics from
these sources may be derived from the textiles in any of a number
of ways including, for example, loose fibers within the textiles
as-made; broken sections of fiber, especially from fiber ends; and
abraded particles from fiber surfaces. All such microplastics may
be produced by wear of the textiles in use, and by damage inflicted
within the textile or on the textile during the laundering/cleaning
process itself.
[0007] Various studies have been, and are being, carried out to
ascertain the extent of the microplastics problem. Of especial
interest is information on the proportions of the various types of
the microplastics. From currently available data, it is estimated
that at least a third of all microplastics pollution is in the form
of microfibers. Of these microfibers, it has been shown that
polyester-based fibers constitute at least half of the man-made
fiber-derived pollution.
[0008] The problem of primary microplastics pollution may be
largely tackled by legislation, i.e., by implementing stricter
rules for plastics producers, and restricting the use of polymer
microparticles in certain consumer products. Indeed, many countries
have already banned the use of polymer microbeads in cosmetic
preparations.
[0009] In the same way, secondary microplastics may be reduced by
the use of legal sanctions on dumping of macroplastics, and/or
greater incentives for plastics recycling. This does not, however,
solve the problem of microplastics from macroplastics already
present in the environment.
[0010] In alternative treatments, some methods for filtering out
microplastics from littoral environments have been suggested, such
as in U.S. Pat. No. 8,944,253.
[0011] In the case of microfibers, legislation is a less useful
weapon, and other approaches of a more technical nature are
required.
[0012] Attempts have been made to provide washing machines with
filters to capture microfibers, such as shown in WO 2019/045632.
However, such filters may rapidly clog up, requiring frequent
cleaning or replacement, and there still exists the need to safely
dispose of the collected microfibers.
[0013] Another possible approach is to provide a simple device
which can be placed in the washing machine alongside the laundry to
prevent microfibers being expelled into the wastewater system. One
such device is a plastic ball-shaped item capable of capturing and
holding microfibers as shown in U.S. D833698 and U.S. Patent
Application Publication No. 2019/0126326, while U.S. Patent
Application Publication No. 2018/0320306 discloses a bag into which
one or more laundry items may be placed, which consists of a
material capable of filtering out microfibers. While such devices
may be effective to some extent, the collected microfibers need to
be removed from these devices and, again, require safe
disposal.
[0014] Rather than attempting to collect microfibers before they
can pass into the environment, it would be better to produce fibers
which have a lower propensity for producing microfibers in the
first place. However, attempting to replace current standard
fiber-forming and textile-applicable fibers with an entirely new
polymer with such properties is not an economically viable option.
Thus, what is required is a means of producing fibers based on
currently used polymers that shed a minimal amount of microfibers
during use and laundering/cleaning whilst being fully suitable for
current coloration, finishing, and fabrication technologies.
[0015] A method of achieving this goal has been suggested by De
Falco et al., Carbohydrate Polymers, 198, 175, (2018), in which
polyamide fibers are surface grafted with a reactive species
containing a pectin group. While their results suggest that this
process is effective in reducing microfiber production from such
fibers, the approach appears to be restricted to polyamides, and
involves a number of chemical and physical processes in addition to
the basic melt-spinning of the fiber.
[0016] Accordingly, there is still a need for the production of
fibers that may help mitigate microplastics pollution.
SUMMARY
[0017] One or more embodiments of the present invention are
generally concerned with a melt-spun polyester fiber for reducing
microplastics pollution. Generally, the melt-spun polyester fiber
is in the form of: (i) a first core-sheath bicomponent polyester
fiber comprising a first core domain and a first sheath domain,
wherein the first core domain comprises a fiber-forming
poly(alkylene terephthalate) and the first sheath domain comprises
a homopolyester or copolyester that is different from the
fiber-forming poly(alkylene terephthalate); (ii) a second
core-sheath bicomponent polyester fiber comprising a second core
domain and a second sheath domain, wherein the second core domain
comprises a fiber-forming poly(alkylene terephthalate) and the
second sheath domain comprises a homopolyester or copolyester and
at least one shed-resistance additive; or (iii) a monocomponent
polyester fiber comprising a fiber-forming poly(alkylene
terephthalate), wherein the monocomponent polyester fiber is at
least partially coated with a shed-resistance coating.
[0018] One or more embodiments of the present invention are
generally concerned with a melt-spun polyester fiber for reducing
microplastics pollution. Generally, the melt-spun polyester fiber
is in the form of: (i) a core-sheath bicomponent polyester fiber
comprising a core domain and a sheath domain, wherein the core
domain comprises a poly(alkylene terephthalate) and said sheath
domain comprises a homopolyester or copolyester and at least one
shed-resistance additive; or (ii) a monocomponent polyester fiber
comprising a poly(alkylene terephthalate), wherein the
monocomponent polyester fiber is at least partially coated with a
shed-resistance coating.
[0019] One or more embodiments of the present invention are
generally concerned with a melt-spun polyester fiber for reducing
microplastics pollution. Generally, the melt-spun polyester fiber
is in the form of: (i) a first core-sheath bicomponent polyester
fiber comprising a first core domain and a first sheath domain,
wherein the first core domain comprises a fiber-forming
poly(alkylene terephthalate) and the first sheath domain comprises
a homopolyester or copolyester that is different from the
fiber-forming poly(alkylene terephthalate); (ii) a second
core-sheath bicomponent polyester fiber comprising a second core
domain and a second sheath domain, wherein the second core domain
comprises a fiber-forming poly(alkylene terephthalate) and the
second sheath domain comprises a homopolyester or copolyester and
at least one shed-resistance additive; or (iii) a monocomponent
polyester fiber comprising a fiber-forming poly(alkylene
terephthalate), wherein the monocomponent polyester fiber is at
least partially coated with a shed-resistance coating. Furthermore,
the melt-spun polyester fiber exhibits a fiber weight loss after a
washing cycle of less than 2 weight percent and a waste microfibers
loss per gram of tested sample after a washing cycle of less than
10 mg of waste microfibers.
[0020] One or more embodiments of the present invention are
generally concerned with a method for producing the melt-spun
polyester fibers described herein. Generally, the methods involve
melt spinning a poly(alkylene terephthalate) to thereby form the
melt-spun polyester fiber.
DETAILED DESCRIPTION
[0021] In order to provide an approach that reduces microfiber
production from fibers and textiles by the greatest possible
amount, and in an economically viable manner, a melt-extrusion
process has been devised for the production of polyester fibers,
which may provide fibers and textiles that have a significantly
reduced propensity for producing microfibers during use and
laundering/cleaning.
[0022] More particularly, the present invention is generally
concerned with producing polyester fibers exhibiting a reduced
propensity for breakage and attritional wear, which may be
primarily produced using standard fiber-forming polyester. This may
be achieved through the use of melt-spinning techniques and/or
downstream physicochemical treatments.
[0023] As discussed below in greater detail, the inventive fibers
described herein may take the form of a variety of embodiments. It
should be noted that all of the following properties and ranges
concerning the inventive fibers are not mutually exclusive (unless
otherwise noted) and, therefore, may be combined in any manner by
one skilled in the art as so desired. For example, any one of the
thickness ranges could be combined with any one of the weight
percentage ranges.
[0024] In one or more embodiments, the inventive fibers can be in
the form of core-sheath fibers comprising different polyesters as
the sheath domain and core domain. Additionally or alternatively,
in various embodiments, the inventive fibers may be in the form of
a core-sheath bicomponent melt-spun fiber, wherein the sheath
comprises the same or a different polyester as the core and the
sheath contains certain additives and/or a coating that aid
reduction in microfiber loss from the inventive fiber.
[0025] Additionally or alternatively, in various embodiments, a
coating/spin-finish may be applied on a melt-spun polyester
monocomponent fiber or the sheath domain of a core-sheath
bicomponent melt-spun fiber, wherein the coating/spin-finish places
special additives onto the monocomponent fiber or the sheath
domain, which may aid in the reduction in microfiber loss.
[0026] As noted above, in certain embodiments, one method of
mitigating microfiber pollution involves melt-spinning a
core-sheath bicomponent fiber having a standard fiber-forming
polyester as a core domain and a sheath domain of an alternative
polyester. The polyester of the sheath domain may be selected from
polyesters that: (i) adhere well to the standard fiber-forming
polyester of the core domain, (ii) have physical properties that
reduce breakage of the core-sheath bicomponent fiber, and/or (iii)
are less susceptible to attritional damage compared to the standard
fiber-forming polyester of the core domain.
[0027] As noted above, in certain embodiments, another method of
mitigating microfiber pollution involves melt-spinning a
core-sheath bicomponent fiber having a standard fiber-forming
polyester core domain and a sheath domain of the same polyester or
a different polyester. In such embodiments, the sheath domain may
contain one or more additives and/or a coating that act in such a
manner as to provide fibers with a reduced propensity for breakage
and/or attritional damage when exposed to laundering processes,
especially when compared to fibers made entirely from the polyester
of the core domain.
[0028] As noted above, in certain embodiments, yet another method
of mitigating microfiber pollution involves melt-spinning a
standard fiber-forming polyester into a monocomponent fiber and
downstream treating the fiber with a lubricant or other coating
formulation, wherein the lubricant or coating formulation contains
one or more additives that, when coated onto or impregnated into
the polyester fiber, act in such a manner as to provide polyester
fibers with reduced propensity for breakage and/or attritional
damage when exposed to laundering processes.
[0029] All of the above-referenced embodiments are described in
greater detail below. It should be noted that, while some of the
following characteristics and properties of the fibers may be
listed separately, it is envisioned that each of the following
characteristics and/or properties of the fibers are not mutually
exclusive and may be combined and present in any combination as
long as they do not conflict.
[0030] In various embodiments, the shed-resistant fibers of the
present invention can comprise core-sheath bicomponent fibers that
exhibit a reduced propensity for breakage and/or attritional wear,
thereby significantly reducing the amount of microfiber pollution
generated from the fibers and textiles made therefrom. In such
embodiments, the core-sheath fibers can be produced from any melt
spinning process known in the art. Generally, a core-sheath fiber
is formed by a core domain being partially or, in most cases, fully
encompassed by the sheath domain.
[0031] In certain embodiments, the core-sheath fibers may comprise
a core domain at least partially formed by a fiber-forming
polyester and a sheath domain at least partially formed by a
different polyester. In alternative embodiments, the core-sheath
fibers may comprise a core domain at least partially formed by a
fiber-forming polyester and a sheath domain at least partially
formed by the same polyester.
[0032] The core-sheath bicomponent fibers may be of any suitable
overall cross-sectional shape, including, but not limited to,
round, square, triangular, flattened, regular multilobal, and
irregular multilobal.
[0033] The core domain of the core-sheath bicomponent fibers may be
of any suitable cross-sectional shape, the shape being the same as
or different from the overall cross-sectional shape of the
core-sheath fibers, including, but not limited to, round, square,
triangular, flattened, regular multilobal, and irregular
multilobal.
[0034] The sheath domain of the core-sheath bicomponent fibers may
cover the entire perimeter of the core domain of the fibers.
Additionally, in various embodiments, the thickness of the sheath
domain may constitute 50% or less, 40% or less, 30% or less, 20% or
less, 10% or less, or 5% or less of the average radius of the
core-sheath fibers. Additionally or alternatively, in various
embodiments, the core-sheath bicomponent fibers may comprise at
least 1, 2, 5, 10, or 15 percent by volume and/or less than 50, 45,
40, 35, 30, 25, 20, 15, or 10 percent by volume of the sheath
domain based on the total volume of the bicomponent fibers.
Furthermore, in various embodiments, the core-sheath bicomponent
fibers may comprise at least 10, 15, 20, 25, 30, 35, 40, 45, or 50
percent by volume and/or less than 95, 90, 85, 80, 75, 70, 65, 60,
or 55 percent by volume of the core domain based on the total
volume of the bicomponent fibers.
[0035] Furthermore, in various embodiments, the interface between
the core domain and the sheath domain of the core-sheath
bicomponent fibers may be smooth, may comprise of regular multiple
peaks and troughs, or may comprise of irregular multiple peaks and
troughs.
[0036] In one or more embodiments, the core domain of the
core-sheath bicomponent fiber may be at least partially formed or
entirely formed from a fiber-forming poly(alkylene terephthalate)
polyester. In such embodiments, the alkylene moiety may be derived
from a C.sub.2-10 aliphatic diol or a derivative thereof, and is
preferably selected from 1,2-ethanediol, 1,3-propanediol, and
1,4-butanediol. In certain embodiments, the core domain of the
core-sheath bicomponent fiber may be at least partially formed or
entirely formed from poly(1,2-ethylene terephthalate),
poly(1,3-propylene terephthalate), poly(1,4-butylene
terephthalate), or combinations thereof. In particular embodiments,
the core domain of the core-sheath bicomponent fiber may be at
least partially formed or entirely formed from poly(1,2-ethylene
terephthalate). In even more particular embodiments, the core
domain of the core-sheath bicomponent fiber may be at least
partially formed or entirely formed from a non-biodegradable
polyester.
[0037] In one or more embodiments, the core domain of the
core-sheath bicomponent fiber may comprise at least 50, 55, 60, 65,
70, 75, 80, 85, 90, 95, or 99 weight percent of at least one
poly(alkylene terephthalate) polyester.
[0038] Additionally or alternatively, in one or more embodiments,
the sheath domain of the core-sheath bicomponent fiber may be at
least partially formed or entirely formed from a fiber-forming
poly(alkylene terephthalate) polyester. In such embodiments, the
alkylene moiety may be derived from a C.sub.2-10 aliphatic diol or
a derivative thereof, and is preferably selected from
1,2-ethanediol, 1,3-propanediol, and 1,4-butanediol. In certain
embodiments, the sheath domain of the core-sheath bicomponent fiber
may be at least partially formed or entirely formed from
poly(1,2-ethylene terephthalate), poly(1,3-propylene
terephthalate), poly(1,4-butylene terephthalate), or combinations
thereof. In particular embodiments, the core domain of the
core-sheath bicomponent fiber may be at least partially formed or
entirely formed from poly(1,4-butylene terephthalate). In
particular embodiments, the sheath domain of the core-sheath
bicomponent fiber may be at least partially formed or entirely
formed from a non-biodegradable polyester.
[0039] Additionally or alternatively, in one or more embodiments,
the sheath domain of the core-sheath bicomponent fiber may comprise
at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 weight
percent of at least one poly(alkylene terephthalate) polyester.
[0040] In one or more embodiments, the sheath domain of the
core-sheath bicomponent fibers may comprise a homopolyester,
wherein the homopolyester is different from or the same as the
polyester forming the core domain of the fiber. In such
embodiments, the homopolyester may comprise a poly(alkylene
carboxylate), a poly(cycloalkylene carboxylate), a poly(arylene
carboxylate), a poly(aralkylene carboxylate), or combinations
thereof. The carboxylate moiety in any of the homopolyesters may be
derived from an aromatic dicarboxylic acid, an araliphatic
dicarboxylic acid, an aliphatic dicarboxylic acid, a cycloaliphatic
dicarboxylic acid, a hetroaromatic dicarboxylic acid, a
heteroaliphatic dicarboxylic acid, a heterocycloaliphatic
dicarboxylic acid, or derivatives thereof.
[0041] In one or more embodiments, the sheath domain of the
core-sheath bicomponent fibers may comprise a copolyester, wherein
the copolyester contains moieties derived from diols or derivatives
thereof and moieties derived from dicarboxylic acids or derivatives
thereof.
[0042] The diols used to produce the polyesters may comprise, for
example, straight chain aliphatic diols, branched aliphatic diols,
unsubstituted cycloaliphatic diols, substituted cycloaliphatic
diols, unsubstituted aromatic diols, substituted aromatic diols,
unsubstituted araliphatic diols, substituted araliphatic diols,
straight chain heteroaliphatic diols, branched heteroaliphatic
diols, unsubstituted heterocycloaliphatic diols, substituted
heterocycloaliphatic diols, unsubstituted heteroaromatic diols,
substituted heteroaromatic diols, unsubstituted heteroaraliphatic
diols, substituted heteroaraliphatic diols, or combinations
thereof.
[0043] The dicarboxylic acids used to produce the polyesters may
comprise, for example, straight chain aliphatic dicarboxylic acids,
branched aliphatic dicarboxylic acids, unsubstituted cycloaliphatic
dicarboxylic acids, substituted dicarboxylic acids, unsubstituted
aromatic dicarboxylic acids, substituted dicarboxylic acids,
unsubstituted araliphatic dicarboxylic acids, substituted
araliphatic dicarboxylic acids, straight chain heteroaliphatic
dicarboxylic acids, branched heteroaliphatic dicarboxylic acids,
unsubstituted heterocycloaliphatic dicarboxylic acids, substituted
heterocycloaliphatic dicarboxylic acids, unsubstituted
heteroaromatic dicarboxylic acids, substituted heteroaromatic
dicarboxylic acids, unsusbstituted heteroaraliphatic dicarboxylic
acids, substituted heteoaraliphatic dicarboxylic acids, or
combinations thereof.
[0044] In one or more embodiments, the sheath domain may comprise
at least two layers, including an inner layer and an outer layer.
The inner layer may be at least partially formed or entirely formed
from a homopolyester or copolyester that exhibits a
compatibilization or adhesion function, while the outer layer may
be at least partially formed or entirely formed from a
homopolyester or copolyester that provides the desired resistance
to breakage and/or attritional damage. In such embodiments, the
homopolyester or copolyester of the inner layer may be different
from that of the outer layer. Furthermore, the inner layer and the
outer layer may be formed from the homopolyesters and copolyesters
hereinbefore described. In certain embodiments, the inner layer may
completely encompass and cover the core domain and the outer layer
may at least partially encompass or entirely encompass the inner
layer.
[0045] In one or more embodiments, the polyesters and/or the diols
and diacids used in the preparation of the polyesters may be
derived from one or more of petrochemical resources, renewable
resources, and/or recycled resources.
[0046] Alternatively, in various embodiments, the shed-resistant
fibers of the present invention can comprise monocomponent fibers
that exhibit a reduced propensity for breakage and/or attritional
wear, thereby significantly reducing the amount of microfiber
pollution generated from the fibers and textiles made therefrom. In
such embodiments, the monocomponent fibers can be produced from any
melt spinning process known in the art. It should be noted that the
monocomponent fibers may be produced by the homopolyesters and
copolyesters hereinbefore described.
[0047] In one or more embodiments, the sheath domain of the
core-sheath fibers or the monocomponent fibers may comprise one or
more shed-resistance additives, which may alter the physical
properties of the sheath domain polyester or of the polyester
forming the monocomponent fiber in such a way so as to form fibers
with a reduced propensity towards breakage and/or attritional
damage. Consequently, this can result in the production of fibers,
yarns, and textiles that may shed significantly lower amounts of
microfibers during use and laundering. In the case of the
core-sheath fibers containing a sheath domain with multiple layers,
the shed-resistance additives may be present in all the layers or
separate distinct layers (e.g., the additives may be present in the
outer layer, but absent in the inner layer). Exemplary
shed-resistance additives can include, for example, lubricants,
impact modifiers, crosslinkers and chain extenders, crystallization
modifiers, low molecular weight substances such as oligomers or
polymers, or combinations thereof. In certain embodiments, the
fibers of the present invention may comprise at least 0.1, 0.5, 1,
2, 3, 4, or 5 and/or not more than 50, 45, 40, 35, 30, 25, 20, 15,
10, 5, or 1 weight percent of at least one shed-resistance
additive.
[0048] Lubricants may include, but are not limited to, one or more
of hydrocarbons, fluorocarbons, or silicones, such as organosilicon
polymers.
[0049] Impact modifiers may include, but are not limited to, one or
more of rubbers, addition copolymers, condensation copolymers,
microspheres, or fibers.
[0050] Crosslinkers and chain extenders may include, but are not
limited to, one or more of polyols, polyamines, polyacids, or
silanes.
[0051] Crystallization modifiers may include, but are not limited
to, one or more crystallization nucleating agents and/or one or
more crystallization suppression agents.
[0052] In one or more embodiments, the sheath domain of the
core-sheath fibers or the monocomponent fibers may comprise a
shed-resistance coating or lubricant. In such embodiments, the
core-sheath fibers or the monocomponent fibers may be surfaced
treated or subjected to a lubricant in a continuous or
discontinuous manner after melt spinning. The coating formulation
or lubricant may contain one or more additives which, when coated
onto, or impregnated into, the outer region of the fibers, provides
the fibers with a reduced propensity towards breakage and/or
attritional damage. Consequently, this can result in the production
of fibers, yarns, and textiles that may shed significantly lower
amounts of microfibers during use and laundering. In certain
embodiments, the fibers of the present invention may comprise at
least 0.1, 0.5, 1, 2, 3, 4, or 5 and/or not more than 50, 45, 40,
35, 30, 25, 20, 15, 10, 5, or 1 weight percent of at least one
shed-resistance coating or lubricant. It should be noted that the
shed-resistance coating or shed-resistance lubricant may comprise
one or more of the above-referenced shed-resistance additives.
[0053] In one or more embodiments, the polyesters forming the core
domain, the sheath domain, and/or the monocomponent fibers may
optionally comprise active formulation additives. Such active
formulation additives may include, but are not limited to,
colorants, UV stabilizers, antioxidants, metal deactivators,
nucleating agents, fire retardants, particulate or fibrous fillers,
antimicrobials, antistatics, processing aids, and combinations
thereof. In certain embodiments, the fibers of the present
invention may comprise at least 0.1, 0.5, 1, 2, 3, 4, or 5 and/or
not more than 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight
percent of at least one active formulation additive.
[0054] In one or more embodiments, the polyesters forming the core
domain, the sheath domain, and/or the monocomponent fibers may not
contain any plasticizers, carbon black, and/or antimicrobial
additives, such as zeolites or metal-based antimicrobial agents
(e.g., metal-based antimicrobial agents, such as silver-based
agents). For instance, the core domain and/or the sheath domain of
the core-sheath fibers or the monocomponent fibers may comprise
less than 1, 0.5, 0.1, 0.05, 0.01, 0.005, or 0.001 weight percent
of plasticizers, carbon black, and/or antimicrobial additives.
[0055] In one or more embodiments, the bicomponent fibers and/or
the monocomponent fibers may comprise a deniers per filament
("dpf") of at least 0.1, 0.5, 1, 2, or 3 and/or not more than 20,
15, 10, 9, 8, 7, 6, 5, or 4 dpf.
[0056] As noted above, the core-sheath fibers and the monocomponent
fibers of the present invention may be melt-spun using equipment
and methods known to those skilled in the art. Exemplary melt
spinning equipment and techniques are described in U.S. Pat. Nos.
5,162,074 and 6,783,854, the disclosures of which are incorporated
herein by reference in their entireties.
[0057] The core-sheath fibers and the monocomponent fibers of the
present invention may be produced in any suitable form, including,
but limited to, multifilament yarns, staple fiber and yarns,
monofilaments, thermoplastic composites, and non-wovens. The fibers
or yarns melt-spun in this manner may be subjected to known
downstream processing methods, including, but not limited to, hot
or cold drawing, texturing, heat-setting, cutting, fusing, and/or
batt formation.
[0058] Due to the unique shed-resistance properties, the fibers of
the present invention may exhibit a fiber weight loss after a
washing cycle of less than 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8,
0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, or 0.01 weight percent.
The washing cycle for this test can be carried out at 40.degree. C.
for 30 minutes at 1,400 rpm and in the absence of a detergent. The
fibers or sample textile can be dried after the washing cycle at
80.degree. C. for 24 hours. The mass of the resulting fiber mass or
sample textile can then be measured and compared against the
initial mass of the fibers or sampled textile to calculate the
percent fiber loss.
[0059] Additionally, due to the unique shed-resistance properties,
the fibers of the present invention may exhibit a waste microfibers
loss per gram of tested sample after the above-referenced washing
cycle of less than 100, 75, 50, 40, 30, 20, 15, 10, 5, 1, 0.5, 0.1,
0.05, or 0.01 mg of waste microfibers. As used herein, "waste
microfibers" refer to fibers derived from the tested sample during
the washing cycle and that have an average length of less than 5 mm
and an average diameter of less than 50 microns.
[0060] Furthermore, due to the unique shed-resistance properties,
the fibers of the present invention may exhibit a percent reduction
in microparticle area of at least 10, 15, 20, 25, 30, 35, 40, or 45
percent and/or not more than 80, 75, 70, 65, 60, 55, 50, 45, 40,
35, or 30 percent, as calculated with ImageJ software after
laundering in accordance with test method AATCC TM 61 and based on
laundering regime 2A or 3A. In regime 2A, the wash canister
contains 150 ml of wash water and 50 steel balls, and the
temperature is set at 49.+-.2.degree. C. In regime 3A, the wash
canister contains 50 ml of wash water and 100 steel balls, with the
temperature set at 71.+-.2.degree. C. In both regimes, the wash
water also contains 0.15% detergent and the wash-cycle time is 45
minutes.
[0061] The fibers or yarns of the present invention may be used in
the manufacture of various woven, knitted, tufted, webbed, and/or
non-woven textiles or in the manufacture of woven, knitted,
non-woven, and/or tufted floorcoverings. The textiles produced from
the fibers or yarns of the present invention may also be used in
the manufacture of finished goods, including, but not limited to,
apparel, towels, soft furnishings, and bedding.
[0062] Moreover, as the core-sheath bicomponent fibers and the
monocomponent fibers of the present invention are made entirely of
polyesters derived from dicarboxylic acids and diols, the fibers or
articles made therefrom can, at the end of their useful life, be
chemically recycled to starting materials using methods known to
those skilled in the art.
[0063] This invention can be further illustrated by the following
examples of embodiments thereof, although it will be understood
that these examples are included merely for the purposes of
illustration and are not intended to limit the scope of the
invention unless otherwise specifically indicated.
EXAMPLES
Examples 1-5 and Comparative Example 6
[0064] Multifilament yarns of 100 denier and comprising 36
filaments per yarn and a final draw ratio of about 2.8 were melt
spun using equipment and processes familiar to those skilled in the
art. The inventive yarns of Examples 1-5 comprised filaments of a
core-sheath bicomponent configuration, wherein the core domain
constituted 85 percent by volume of the overall filament and the
sheath domain constituted 15 percent by volume of the overall
filament. Furthermore, the core domains of Examples 1-5 were formed
from poly(ethylene terephthalate) ("PET") and the sheath domain
were formed from a thermoplastic polyester optionally containing a
shed-resistant additive package comprising polymeric and/or
non-polymeric constituents. The formulations of the sheath domains
in Examples 1-5 are provided below in TABLE 1.
TABLE-US-00001 TABLE 1 Example Sheath Formulation 1 PET containing
an additive package of organosilicon polymers for softening and/or
smoothing of the matrix polyester 2 PET containing an additive
package of active adjuvants for thermal and thermo- oxidative
stabilization of the matrix polyester 3 PET containing an additive
package consisting of active adjuvants for hydrolytic stabilization
and intrinsic viscosity enhancement of matrix polyester 4 PET
containing an additive package of active adjuvants for
crystallization control of the matrix polyester 5 Poly(butylene
terephthalate)
[0065] For Comparative Example 6, a yarn consisting of
poly(ethylene terephthalate) monofilaments of the same overall
denier and fiber count was melt-spun under the same conditions as
used for the manufacture of Examples 1-5.
[0066] The inventive yarns noted in TABLE 1, along with the
comparative poly(ethylene terephthalate) yarn, were each single
thread-line jersey knitted into socks. Two distinctive analytical
methods were used to describe the rate of microfiber shed: (i)
analysis of deposited microfiber shed on filtration media and (ii)
particle analysis of shed microfibers using ImageJ.
[0067] For testing the accelerated wear and collected microfiber
shed, samples measuring 3.5 inches by 5 inches were cut from the
socks, and the edges thereof heat-sealed and trimmed to remove
rough edges.
[0068] The aforementioned samples were then subjected to simulated
wear using a model CM1 Crockmeter (Atlas Electric Devices). Fabric
samples were attached to the stationary bottom portion of the
Crockmeter, while a stainless-steel screen with 25 mm pore size was
attached to the oscillating upper portion. The stainless-steel
screen was oscillated against each fabric surface 30 times to
generate wear on the samples.
[0069] Visual examination of the tested samples noted that all
inventive samples exhibited less wear than the comparative sample
when passed through a multi-stage filter of 200.times.200 .mu.m,
100.times.100 .mu.m, 25.times.25 .mu.m, and 450 nm, in series. A
quantitative measurement, using the same abrasion and laundering
procedure of the replicate samples described above with the
Crockmeter, was collected using a single 10.times.10 micrometer
filter. More particularly, after the laundering procedure with the
Crockmeter, the samples were placed in 1 liter Laundr-O-meter
canisters and tested using optimized conditions to generate wear on
the samples (2 hours, 45.degree. C., 50 stainless steel balls, 200
g DI water). The fabric was then allowed to dry. The resulting
laundry water was also filtered using an approximate 10 .mu.m
filter to compare lint generation between samples (sample mass).
The collected material was weighed, and the results are given in
TABLE 2, below.
TABLE-US-00002 TABLE 2 Percent Reduction in Microparticle Example
Mass Generated in Laundering 1 20 2 39 3 41 4 35 5 41
[0070] For particle analysis in laundering water, testing of
samples was carried out using a standard test apparatus, in the
form of an SDL Atlas Laundr-O-Meter M228 Rotowash. The test
protocols used were those described in the test method AATCC TM 61
"Test method for colorfastness in laundering," which is
incorporated herein by reference in its entirety.
[0071] Two laundering regimes were used in the tests in an attempt
to simulate both standard and harsher washing cycles likely to be
encountered during domestic or commercial laundering. The two
regimes were referred to as "2A" and "3A." In regime 2A, the wash
canister contained 150 ml of wash water and 50 steel balls, and the
temperature was set at 49.+-.2.degree. C. In regime 3A, the wash
canister contained 50 ml of wash water and 100 steel balls, with
the temperature set at 71.+-.2.degree. C. In both regimes, the wash
water also contained 0.15% detergent and the wash-cycle time was 45
minutes.
[0072] Samples of the test fabrics and samples of the control
fabrics were subjected to both laundering regimes in the device
canisters, along with a canister containing no sample as a blank.
Following laundering, water samples were extracted from the wash
canisters and prepared for imaging using microscopy.
[0073] Results of the laundering tests are provided below in TABLE
3 as a percentage reduction in microparticle area as calculated in
ImageJ using the particle analysis tools of the ImageJ software,
with respect to the control poly(ethylene terephthalate)
fabric.
TABLE-US-00003 TABLE 3 Example Regime 2A Regime 3A 1 31 10 2 35 28
3 41 47 4 3 34 5 42 --
Definitions
[0074] It should be understood that the following is not intended
to be an exclusive list of defined terms. Other definitions may be
provided in the foregoing description, such as, for example, when
accompanying the use of a defined term in context.
[0075] As used herein, the terms "a," "an," and "the" mean one or
more.
[0076] As used herein, the term "and/or," when used in a list of
two or more items, means that any one of the listed items can be
employed by itself or any combination of two or more of the listed
items can be employed. For example, if a composition is described
as containing components A, B, and/or C, the composition can
contain A alone; B alone; C alone; A and B in combination; A and C
in combination, B and C in combination; or A, B, and C in
combination.
[0077] As used herein, the terms "comprising," "comprises," and
"comprise" are open-ended transition terms used to transition from
a subject recited before the term to one or more elements recited
after the term, where the element or elements listed after the
transition term are not necessarily the only elements that make up
the subject.
[0078] As used herein, the terms "having," "has," and "have" have
the same open-ended meaning as "comprising," "comprises," and
"comprise" provided above.
[0079] As used herein, the terms "including," "include," and
"included" have the same open-ended meaning as "comprising,"
"comprises," and "comprise" provided above.
Numerical Ranges
[0080] The present description uses numerical ranges to quantify
certain parameters relating to the invention. It should be
understood that when numerical ranges are provided, such ranges are
to be construed as providing literal support for claim limitations
that only recite the lower value of the range as well as claim
limitations that only recite the upper value of the range. For
example, a disclosed numerical range of 10 to 100 provides literal
support for a claim reciting "greater than 10" (with no upper
bounds) and a claim reciting "less than 100" (with no lower
bounds).
CLAIMS NOT LIMITED TO DISCLOSED EMBODIMENTS
[0081] The preferred forms of the invention described above are to
be used as illustration only and should not be used in a limiting
sense to interpret the scope of the present invention.
Modifications to the exemplary embodiments, set forth above, could
be readily made by those skilled in the art without departing from
the spirit of the present invention.
[0082] The inventors hereby state their intent to rely on the
Doctrine of Equivalents to determine and assess the reasonably fair
scope of the present invention as it pertains to any apparatus not
materially departing from but outside the literal scope of the
invention as set forth in the following claims.
* * * * *