US20050208286A1 - Polymeric composites having enhanced reversible thermal properties and methods of forming thereof - Google Patents

Polymeric composites having enhanced reversible thermal properties and methods of forming thereof Download PDF

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Publication number
US20050208286A1
US20050208286A1 US11/078,656 US7865605A US2005208286A1 US 20050208286 A1 US20050208286 A1 US 20050208286A1 US 7865605 A US7865605 A US 7865605A US 2005208286 A1 US2005208286 A1 US 2005208286A1
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Prior art keywords
polymeric
blend
polymeric material
phase change
dispersing
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US11/078,656
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Mark Hartmann
Monte Magill
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Latent Heat Solutions LLC
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Outlast Technologies LLC
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Priority claimed from US09/777,512 external-priority patent/US6793856B2/en
Application filed by Outlast Technologies LLC filed Critical Outlast Technologies LLC
Priority to US11/078,656 priority Critical patent/US20050208286A1/en
Assigned to OUTLAST TECHNOLOGIES, INC. reassignment OUTLAST TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MAGILL, MONTE C., HARTMANN, MARK H.
Publication of US20050208286A1 publication Critical patent/US20050208286A1/en
Priority to CN201210440162.8A priority patent/CN103061039B/zh
Priority to KR1020137027992A priority patent/KR101455562B1/ko
Priority to EP10182697.2A priority patent/EP2392712B1/en
Priority to CN2006800077276A priority patent/CN101208465B/zh
Priority to PCT/US2006/006216 priority patent/WO2006098851A2/en
Priority to EP20060735750 priority patent/EP1856317B8/en
Priority to KR1020077023012A priority patent/KR101396006B1/ko
Priority to JP2008500731A priority patent/JP2008533238A/ja
Priority to KR1020147016979A priority patent/KR101563177B1/ko
Priority to TW95108055A priority patent/TWI439499B/zh
Assigned to SILICON VALLEY BANK reassignment SILICON VALLEY BANK SECURITY AGREEMENT Assignors: OUTLAST TECHNOLOGIES LLC
Assigned to OUTLAST TECHNOLOGIES LLC reassignment OUTLAST TECHNOLOGIES LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OUTLAST TECHNOLOGIES, INC.
Priority to JP2013086016A priority patent/JP2013163886A/ja
Priority to JP2014003397A priority patent/JP5969519B2/ja
Priority to US14/492,691 priority patent/US20150018480A1/en
Priority to JP2015208052A priority patent/JP6105701B2/ja
Priority to JP2016047274A priority patent/JP6208793B2/ja
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/01—Hydrocarbons
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K5/00—Heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants; Materials for the production of heat or cold by chemical reactions other than by combustion
    • C09K5/02—Materials undergoing a change of physical state when used
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/20—Compounding polymers with additives, e.g. colouring
    • C08J3/201—Pre-melted polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/20—Compounding polymers with additives, e.g. colouring
    • C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
    • C08J3/226—Compounding polymers with additives, e.g. colouring using masterbatch techniques using a polymer as a carrier
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K9/00—Use of pretreated ingredients
    • C08K9/10—Encapsulated ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/06—Polyethene
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D1/00—Treatment of filament-forming or like material
    • D01D1/06—Feeding liquid to the spinning head
    • D01D1/065—Addition and mixing of substances to the spinning solution or to the melt; Homogenising
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D20/00—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00
    • F28D20/02—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00 using latent heat
    • F28D20/023—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00 using latent heat the latent heat storage material being enclosed in granular particles or dispersed in a porous, fibrous or cellular structure
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00—Properties
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/14—Thermal energy storage
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Definitions

  • the invention relates to polymeric composites and their manufacture. More particularly, the invention relates to polymeric composites including phase change materials that are useful in the manufacture of synthetic fibers.
  • an acrylic fiber includes a long-chain synthetic polymer characterized by the presence of acrylonitrile units
  • a nylon fiber includes a long-chain synthetic polyamide polymer characterized by the presence of an amide group —CONH—
  • a polyester fiber includes a long-chain synthetic polymer having at least 85 percent by weight of an ester of a substituted aromatic carboxylic acid unit
  • a polypropylene fiber includes a long-chain synthetic crystalline polymer having at least 85 percent by weight of an olefin unit and typically having a molecular weight of about 40,000 or more.
  • the melt spinning process is of particular interest, since a large portion of the synthetic fibers that are used in the textile industry are manufactured by this technique.
  • the melt spinning process generally involves passing a molten polymeric material through a device that is known as a spinneret to thereby form a set of individual synthetic fibers. Once formed, the synthetic fibers can be collected into a strand or cut into staple fibers. Synthetic fibers can be used to make woven or non-woven fabrics, or, alternatively, synthetic fibers can be wound into a yarn to be used thereafter in a weaving or a knitting process to form a synthetic fabric.
  • Phase change materials have been incorporated into acrylic fibers to enable the fibers to provide enhanced reversible thermal properties and to enable fabrics made from such fibers to perform similar functions. This is readily accomplished, in part due to the high levels of volatile materials (e.g., solvents) typically associated with the wet solution process of forming acrylic fibers. However, it is more problematic to incorporate phase change materials into melt spun synthetic fibers, since high levels of volatile materials are typically not present or desired in the melt spinning process. Previous attempts to incorporate phase change materials into melt spun synthetic fibers typically involved mixing the phase change materials with a standard fiber-grade thermoplastic polymer to form a blend and subsequently melt spinning this blend to form the synthetic fibers.
  • volatile materials e.g., solvents
  • the invention relates to a method of manufacturing a polymeric composite.
  • the method includes: (a) mixing a set of microcapsules containing a phase change material with a dispersing polymeric material to form a first blend, the dispersing polymeric material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.; and (b) processing the first blend to form the polymeric composite.
  • the method includes: (a) melting a first temperature regulating material to form a first melt; (b) dispersing a second temperature regulating material in the first melt to form a first blend; (c) processing the first blend to form granules; (d) melting a matrix polymeric material to form a second melt; (e) dispersing the granules in the second melt to form a second blend; and (f) processing the second blend to form the polymeric composite.
  • the method includes: (a) melting a first polymeric material to form a first melt, the first polymeric material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.; (b) dispersing a temperature regulating material in the first melt to form a first blend, the temperature regulating material including a phase change material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.; (c) mixing the first blend with a second polymeric material to form a second blend; and (d) processing the second blend to form the polymeric composite.
  • the invention in another aspect, relates to a polymeric composite.
  • the polymeric composite includes: (a) a polymeric material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.; and (b) a set of microcapsules dispersed in the polymeric material, the microcapsules containing a phase change material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.
  • the polymeric composite includes a blend of a polymeric material and a non-encapsulated phase change material.
  • the polymeric material has a partial affinity for the non-encapsulated phase change material, such that the non-encapsulated phase change material forms a set of domains dispersed in the polymeric material.
  • the non-encapsulated phase change material has a latent heat of at least 60 J/g and a transition temperature in the range of 10° C. to 50° C.
  • FIG. 1 illustrates a manufacturing process to form a polymeric composite in accordance with an embodiment of the invention.
  • FIG. 2 illustrates a manufacturing process to form a polymeric composite in accordance with another embodiment of the invention.
  • FIG. 3 illustrates a manufacturing process to form a polymeric composite in accordance with a further embodiment of the invention.
  • Embodiments of the invention relate to polymeric composites having enhanced reversible thermal properties and methods of manufacturing the same.
  • Polymeric composites in accordance with various embodiments of the invention have the ability to absorb and release thermal energy under different environmental conditions.
  • the polymeric composites can exhibit, for example, improved dispersion or higher loading levels of a phase change material.
  • the polymeric composites can be formed in a variety of forms or shapes, such as pellets, fibers, flakes, sheets, films, rods, and so forth.
  • the polymeric composites can be used as is or incorporated in various articles to provide a thermal regulating property while providing improved strength to the articles.
  • polymeric composites in accordance with various embodiments of the invention can be used in textiles (e.g., fabrics), apparel (e.g., outdoor clothing, drysuits, and protective suits), footwear (e.g., socks, boots, and insoles), medical products (e.g., thermal blankets, therapeutic pads, incontinent pads, and hot/cold packs), containers and packagings (e.g., beverage and food containers, food warmers, seat cushions, and circuit board laminates), buildings (e.g., insulation in walls or ceilings, wallpaper, curtain linings, pipe wraps, carpets, and tiles), appliances (e.g., insulation in house appliances), and other products (e.g., automotive lining material, sleeping bags, and bedding).
  • textiles e.g., fabrics
  • apparel e.g., outdoor clothing, drysuits, and protective suits
  • footwear e.g., socks, boots, and insoles
  • medical products e.g., thermal blankets, therapeutic pads, incontinent pads, and hot/cold packs
  • Polymeric composites in accordance with various embodiments of the invention can be processed to form a variety of articles having enhanced reversible thermal properties.
  • polymeric composites can be formed as pellets that are useful to form synthetic fibers, for injection molding processes, or for extrusion processes. Use of these pellets can provide benefits that are achieved by incorporating a phase change material into a variety of articles, which articles include, for example, fibers such as acrylic fibers, nylon fibers, polyester fibers, polyethylene fibers, and polypropylene fibers; films; foams; and injection molded articles.
  • Polymeric composites in accordance with various embodiments of the invention can provide an improved level of comfort when incorporated in articles such as apparel or footwear.
  • the articles can provide such improved level of comfort under different or changing environmental conditions.
  • the use of phase change materials allows the articles to provide “multi-directional” or “dynamic” thermal regulation rather than “unidirectional” or “static” thermal regulation.
  • the articles can absorb thermal energy in warm weather as well as release thermal energy in cold weather. In such manner, the articles can provide cooling in warm weather and heating in cold weather, thus maintaining a desired level of comfort under different weather conditions.
  • the articles can adapt or adjust their thermal regulating property under changing environmental conditions. In such manner, the articles can be capable of multiple uses, such as for both warm weather and cold weather.
  • the articles can adapt or adjust their thermal regulating property without requiring an external triggering mechanism, such as moisture or sunlight.
  • polymeric composites in accordance with various embodiments of the invention when incorporated, for example, in apparel or footwear can provide other improvements in a level of comfort.
  • articles incorporating the polymeric composites can provide a reduction in an individual's skin moisture, such as due to perspiration.
  • the articles can lower the temperature or the relative humidity of the skin, thereby providing a lower degree of skin moisture and a higher level of comfort.
  • the use of specific materials and specific apparel or footwear design features can further enhance the level of comfort.
  • the articles can be used in conjunction with certain additives, treatments, or coatings to provide further benefits in thermal regulating and moisture management properties.
  • a polymeric composite according to some embodiments of the invention can include one or more materials.
  • the polymeric composite can include a temperature regulating material, a dispersing polymeric material, and a matrix polymeric material.
  • the polymeric composite is a liquid melt mixture or a solidified melt mixture of the temperature regulating material, the dispersing polymeric material, and the matrix polymeric material.
  • the temperature regulating material is uniformly dispersed within the polymeric composite.
  • the dispersion of the temperature regulating material can be varied within the polymeric composite.
  • the dispersing polymeric material and the matrix polymeric material can be the same or different.
  • the temperature regulating material, the dispersing polymeric material, and the matrix polymeric material can be omitted for certain embodiments of the invention.
  • the polymeric composite can include the temperature regulating material and the dispersing polymeric material without requiring the matrix polymeric material.
  • the polymeric composite can further include one or more additives, such as water, surfactants, dispersants, anti-foam agents (e.g., silicone containing compounds and flourine containing compounds), antioxidants (e.g., hindered phenols and phosphites), thermal stabilizers (e.g., phosphites, organophosphorous compounds, metal salts of organic carboxylic acids, and phenolic compounds), light or UV stabilizers (e.g., hydroxy benzoates, hindered hydroxy benzoates, and hindered amines), light or UV absorbing additives (e.g., ceramic particles of Group IV transition metal carbides and oxides), microwave absorbing additives (e.g., multifunctional primary alcohols, glycerine, and carbon), reinforcing-fibers (e.g., carbon fibers, aramid fibers, and glass fibers), conductive additives, such as water, surfactants, dispersants, anti-foam agents (e.g., silicone containing
  • a temperature regulating material can include one or more phase change materials.
  • a phase change material can include any substance (or mixture of substances) that has the capability of absorbing or releasing thermal energy to reduce or eliminate heat flow at or within a temperature stabilizing range.
  • the temperature stabilizing range can include a particular transition temperature or a range of transition temperatures.
  • a phase change material used in conjunction with various embodiments of the invention can be capable of inhibiting a flow of thermal energy during a time when the phase change material is absorbing or releasing heat, typically as the phase change material undergoes a transition between two states (e.g., liquid and solid states, liquid and gaseous states, solid and gaseous states, or two solid states).
  • latent heat can refer to an amount of heat absorbed or released by a substance (or mixture of substances) as it undergoes a transition between two states.
  • Thermal energy can be stored or removed from a phase change material, and the phase change material typically can be effectively recharged by a source of heat or cold.
  • a polymeric composite can be formed for any application thereof.
  • a phase change material can be a solid/solid phase change material.
  • a solid/solid phase change material is a type of phase change material that typically undergoes a transition between two solid states (e.g., a crystalline or mesocrystalline phase transformation) and, hence, typically does not become a liquid during use.
  • a phase change material can include a mixture of two or more substances. By selecting two or more different substances and forming a mixture, a temperature stabilizing range can be adjusted for any particular application of a polymeric composite. According to some embodiments of the invention, a mixture of two or more different substances can exhibit two or more distinct transition temperatures or a single modified transition temperature when incorporated in a polymeric composite.
  • Phase change materials that can be incorporated in polymeric composites in accordance with various embodiments of the invention include a variety of organic and inorganic substances.
  • phase change materials include hydrocarbons (e.g., straight chain alkanes or paraffinic hydrocarbons, branched-chain alkanes, unsaturated hydrocarbons, halogenated hydrocarbons, and alicyclic hydrocarbons), hydrated salts (e.g., calcium chloride hexahydrate, calcium bromide hexahydrate, magnesium nitrate hexahydrate, lithium nitrate trihydrate, potassium fluoride tetrahydrate, ammonium alum, magnesium chloride hexahydrate, sodium carbonate decahydrate, disodium phosphate dodecahydrate, sodium sulfate decahydrate, and sodium acetate trihydrate), waxes, oils, water, fatty acids, fatty acid esters, dibasic acids, dibasic esters, 1-halides, primary alcohols, aromatic compounds, clathrates,
  • phase change material will typically be dependent upon a desired transition temperature or a desired application of a resulting polymeric composite.
  • a phase change material having a transition temperature near room temperature can be desirable for applications in which the resulting polymeric composite is incorporated into apparel or footwear to maintain a comfortable temperature for a user.
  • a phase change material according to some embodiments of the invention can have a transition temperature ranging from about ⁇ 40° C. to about 125° C., such as from about ⁇ 40° C. to about 100° C. or from about ⁇ 5° C. to about 125° C.
  • the phase change material can have a transition temperature ranging from about 0° C. to about 50° C., such as from about 10° C. to about 50° C., from about 15° C. to about 45° C., from about 22° C. to about 40° C., or from about 22° C. to about 28° C.
  • the phase change material according to some embodiments of the invention can have a latent heat that is at least about 40 J/g, such as at least about 50 J/g, at least about 60 J/g, at least about 70 J/g, at least about 80 J/g, at least about 90 J/g, or at least about 100 J/g.
  • the phase change material can have a latent heat ranging from about 40 J/g to about 400 J/g, such as from about 60 J/g to about 400 J/g, from about 80 J/g to about 400 J/g, or from about 100 J/g to about 400 J/g.
  • phase change materials include paraffinic hydrocarbons having from 10 to 44 carbon atoms (i.e., C 10 -C 44 paraffinic hydrocarbons).
  • Table 1 provides a list of C 13 - C 28 paraffinic hydrocarbons that can be used as phase change materials in the polymeric composites described herein.
  • the number of carbon atoms of a paraffinic hydrocarbon typically correlates with its melting point.
  • n-Octacosane which includes 28 straight chain carbon atoms per molecule, has a melting point of 61.4° C.
  • n-Tridecane which includes 13 straight chain carbon atoms per molecule, has a melting point of ⁇ 5.5° C.
  • n-Octadecane which includes 18 straight chain carbon atoms per molecule and has a melting point of 28.2° C.
  • phase change materials include polymeric phase change materials having transition temperatures suitable for a desired application of a polymeric composite (e.g., from about 22° C. to about 40° C. for clothing applications).
  • a polymeric phase change material can include a polymer (or a mixture of polymers) having a variety of chain structures that include one or more types of monomer units.
  • polymeric phase change materials can include linear polymers, branched polymers (e.g., star branched polymers, comb branched polymers, or dendritic branched polymers), or mixtures thereof.
  • a polymeric phase change material desirably includes a linear polymer or a polymer with a small amount of branching to allow for a greater density and a greater degree of ordered molecular packing and crystallization. Such greater degree of ordered molecular packing and crystallization can lead to a larger latent heat and a narrower temperature stabilizing range (e.g., a well-defined transition temperature).
  • a polymeric phase change material can include a homopolymer, a copolymer (e.g., terpolymer, statistical copolymer, random copolymer, alternating copolymer, periodic copolymer, block copolymer, radial copolymer, or graft copolymer), or a mixture thereof.
  • Properties of one or more types of monomer units forming a polymeric phase change material can affect a transition temperature of the polymeric phase change material. Accordingly, the selection of the monomer units can be dependent upon a desired transition temperature or a desired application of polymeric composites that include the polymeric phase change material. As one of ordinary skill in the art will understand, the reactivity and functionality of a polymer can be altered by addition of a functional group, such as amine, amide, carboxyl, hydroxyl, ester, ether, epoxy, anhydride, isocyanate, silane, ketone, and aldehyde. Also, a polymeric phase change material can include a polymer capable of crosslinking, entanglement, or hydrogen bonding in order to increase its toughness or its resistance to heat, moisture, or chemicals.
  • a polymeric phase change material can include a polymer (or a mixture of polymers) having a particular molecular weight or a particular range of molecular weights.
  • the term “molecular weight” can refer to a number average molecular weight, a weight average molecular weight, or a melt index of a polymer (or a mixture of polymers).
  • a polymeric phase change material can be desirable as a result of having a higher molecular weight, a larger molecular size, or a higher viscosity relative to non-polymeric phase change materials (e.g., paraffinic hydrocarbons).
  • a polymeric phase change material can exhibit a lesser tendency to leak from a polymeric composite during processing or during end use.
  • a polymeric phase change material can include polymers having a number average molecular weight ranging from about 400 to about 5,000,000, such as from about 2,000 to about 5,000,000, from about 8,000 to about 100,000, or from about 8,000 to about 15,000.
  • a polymeric phase change material When incorporated within a synthetic fiber, for example, its larger molecular size or its higher viscosity can prevent a polymeric phase change material from flowing through an exterior of the fiber.
  • a polymeric phase change material can provide improved mechanical properties (e.g., ductility, tensile strength, and hardness) when incorporated in articles in accordance with various embodiments of the invention.
  • a polymeric phase change material having a desired transition temperature can be combined with a polymeric material (e.g., a dispersing polymeric material or a matrix polymeric material) to form a polymeric composite.
  • a polymeric phase change material can provide adequate mechanical properties such that it can be used to form a polymeric composite without requiring another polymeric material, thus allowing for a higher loading level of the polymeric phase change material and improved thermal regulating properties.
  • a polymeric phase change material can be used as is or can serve as a dispersing polymeric material to form a polymeric composite.
  • polyethylene glycols can be used as a phase change material in some embodiments of the invention.
  • the number average molecular weight of polyethylene glycol typically correlates with its melting point.
  • polyethylene glycols having a number average molecular weight in the range of about 570 to about 630 typically will have a melting point of about 20° C. to about 25° C., making them desirable for clothing applications.
  • Other polyethylene glycols that can be useful at other temperature stabilizing ranges include polyethylene glycols having a number average molecular weight of about 400 and a melting point in the range of about 4° C.
  • polyethylene glycols having a number average molecular weight in the range of about 1,000 to about 1,500 and a melting point in the range of about 42° C. to about 48° C. polyethylene glycols having a number average molecular weight of about 6,000 and a melting point in the range of about 56° C. to about 63° C.
  • CarbowaxTM 400, 1500, and 6000, available from The Dow Chemical Company, Midland, Mich. polyethylene glycols having a number average molecular weight in the range of about 1,000 to about 1,500 and a melting point in the range of about 42° C. to about 48° C.
  • polyethylene glycols having a number average molecular weight of about 6,000 and a melting point in the range of about 56° C. to about 63° C. e.g., CarbowaxTM 400, 1500, and 6000, available from The Dow Chemical Company, Midland, Mich.
  • Additional useful phase change materials include polymeric phase change materials based on polyethylene glycols that are endcapped with fatty acids.
  • polytetramethylene glycol fatty acid diesters having a melting point in the range of about 22° C. to about 35° C. can be formed from polyethylene glycols having a number average molecular weight in the range of about 400 to about 600 that are endcapped with stearic acid or lauric acid.
  • Further useful phase change materials include polymeric phase change materials based on tetramethylene glycol.
  • polytetramethylene glycols having a number average molecular weight in the range of about 1,000 to about 1,800 typically have a melting point in the range of about 19° C. to about 36° C.
  • Polyethylene oxides having a melting point in the range of about 60° C. to about 65° C. also can be used as phase change materials in some embodiments of the invention.
  • polymeric phase change materials can include homopolymers having a melting point in the range of about 0° C. to about 50° C. that can be formed using conventional polymerization processes.
  • Table 2 sets forth melting points of various homopolymers that can be formed from different types of monomer units.
  • phase change materials include polyesters having a melting point in the range of about 0° C. to about 40° C. that can be formed, for example, by polycondensation of glycols (or their derivatives) with diacids (or their derivatives).
  • Table 3 sets forth melting points of polyesters that can be formed with various combinations of glycols and diacids.
  • a polymeric phase change material having a desired transition temperature can be formed by reacting a phase change material (e.g., a phase change material discussed above) with a polymer (or a mixture of polymers).
  • a phase change material e.g., a phase change material discussed above
  • a polymer or a mixture of polymers.
  • phase change material e.g., a phase change material discussed above
  • a phase change material e.g., a phase change material discussed above
  • a polymer or a mixture of polymers.
  • phase change material e.g., a phase change material discussed above
  • a polymer or a mixture of polymers.
  • phase change material e.g., a phase change material discussed above
  • dodecanoic acid i.e., lauric acid
  • phase change materials e.g., phase change materials with one or more functional. groups such as amine, carboxyl, hydroxyl, epoxy, silane, sulfuric, and so forth
  • Polymeric phase change materials having desired transition temperatures can be formed from various types of monomer units.
  • a polymeric phase change material can be formed by polymerizing octadecyl methacrylate, which can be formed by esterification of octadecyl alcohol with methacrylic acid.
  • polymeric phase change materials can be formed by polymerizing a polymer (or a mixture of polymers).
  • poly-(polyethylene glycol) methacrylate, poly-(polyethylene glycol) acrylate, poly-(polytetramethylene glycol) methacrylate, and poly-(polytetramethylene glycol) acrylate can be formed by polymerizing polyethylene glycol methacrylate, polyethylene glycol acrylate, polytetramethylene glycol methacrylate, and polytetramethylene glycol acrylate, respectively.
  • the monomer units can be formed by esterification of polyethylene glycol (or polytetramethylene glycol) with methacrylic acid (or acrylic acid).
  • polyglycols can be esterified with allyl alcohol or trans-esterified with vinyl acetate to form polyglycol vinyl ethers, which in turn can be polymerized to form poly-(polyglycol) vinyl ethers.
  • polymeric phase change materials can be formed from homologues of polyglycols, such as ester or ether endcapped polyethylene glycols and polytetramethylene glycols.
  • a temperature regulating material can include a phase change material in a raw form (e.g., the phase change material is non-encapsulated at either a micro or macro level, i.e., not micro- or macroencapsulated).
  • the phase change material in the raw form can be provided as a solid in a variety of forms (e.g., bulk form, powders, pellets, granules, flakes, and so forth) or as a liquid in a variety of forms (e.g., molten form, dissolved in a solvent, and so forth).
  • a temperature regulating material can include a containment structure that encapsulates, contains, surrounds, absorbs, or reacts with a phase change material.
  • the containment structure can facilitate handling of the phase change material while offering a degree of protection to the phase change material from manufacturing conditions (e.g., high temperature or shear forces) associated with forming a polymeric composite or articles made from the polymeric composite.
  • the containment structure can serve to reduce or prevent leakage of the phase change material from the polymeric composite or from an article formed therefrom.
  • a temperature regulating material can include microcapsules that contain a phase change material, which microcapsules can be uniformly, or non-uniformly, dispersed within a polymeric composite.
  • the microcapsules can be formed as hollow shells enclosing the phase change material and can include individual microcapsules formed in a variety of regular or irregular shapes (e.g., spherical, ellipsoidal, and so forth) and sizes.
  • the individual microcapsules can have the same or different shapes or sizes.
  • the microcapsules can have a maximum linear dimension (e.g., diameter) ranging from about 0.01 to about 100 microns.
  • the microcapsules can have a generally spherical shape and a maximum linear dimension (e.g., diameter) ranging from about 0.5 to about 10 microns, such as from about 0.5 to about 3 microns.
  • a containment structure include silica particles (e.g., precipitated silica particles, fumed silica particles, and mixtures thereof), zeolite particles, carbon particles (e.g., graphite particles, activated carbon particles, and mixtures thereof), and absorbent materials (e.g., absorbent polymeric materials, superabsorbent materials, cellulosic materials, poly(meth)acrylate materials, metal salts of poly(meth)acrylate materials, and mixtures thereof).
  • a temperature regulating material can include silica particles, zeolite particles, carbon particles, or an absorbent material impregnated with a phase change material.
  • a polymeric composite can include up to about 100 percent by weight of a temperature regulating material. In some embodiments, a polymeric composite can include from about 5 percent to about 70 percent by weight of a temperature regulating material. Thus, according to some embodiments of the invention, a polymeric composite can include from about 10 percent to about 30 percent or from about 15 percent to about 25 percent by weight of a temperature regulating material. And, according to other embodiments, a polymeric composite can include about 15 percent by weight of a temperature regulating material. As further discussed below, some embodiments of the invention employ water-wetted microcapsules containing a phase change material to form a polymeric composite. In such embodiments, a polymeric composite can include an amount of water that is typically less than about 1 percent by weight.
  • a polymeric composite can include two or more temperature regulating materials that differ from one another in some fashion.
  • the two temperature regulating materials can include two different phase change materials or a phase change material in a raw form and a phase change material in an encapsulated form.
  • the phase change material in the raw form can include a polymeric phase change material, which can serve as a dispersing polymeric material to form the polymeric composite.
  • a dispersing polymeric material can include any polymer (or mixture of polymers) that facilitates incorporating a temperature regulating material in a polymeric composite.
  • the polymeric phase change material can be selected to have the characteristics discussed herein for the dispersing polymeric material.
  • the dispersing polymeric material can be compatible or miscible with or have an affinity for the temperature regulating material. In some embodiments of the invention, such affinity can depend on, for example, similarity of solubility parameters, polarities, hydrophobic characteristics, or hydrophilic characteristics of the dispersing polymeric material and the temperature regulating material.
  • such affinity can facilitate dispersion of the temperature regulating material in an intermediate molten or liquid form of the polymeric composite during its manufacture (e.g., in a melt of the dispersing polymeric material) and, thus, ultimately can facilitate incorporation of more uniform or greater amounts or loading level of a phase change material in the polymeric composite.
  • the temperature regulating material includes a containment structure that contains a phase change material
  • the dispersing polymeric material can be selected for its affinity for the containment structure in conjunction with, or as an alternative to, its affinity for the phase change material.
  • the dispersing polymeric material can be selected to have an affinity for the microcapsules (e.g., for a material or materials of which the microcapsules are formed). Such affinity can facilitate dispersion of the microcapsules containing the phase change material in an intermediate molten or liquid form of the polymeric composite (e.g., in a melt of the dispersing polymeric material) and, thus, ultimately can facilitate incorporation of more uniform or greater amounts or loading level of the phase change material in the polymeric composite.
  • the dispersing polymeric material can be selected to include a polymer that is the same as or similar to a polymer forming the microcapsules (e.g., if the microcapsules include nylon shells, the dispersing polymeric material can be selected to include nylon).
  • the dispersing polymeric material can be selected to include a polymer with one or more functional groups, such as amine or epoxy, to provide such affinity for the microcapsules (e.g., if the microcapsules include one or more carboxyl groups, the dispersing polymeric material can be selected to include a polymer with one or more epoxy groups, such as polystearyl methacrylate-co-glycidyl methacrylate).
  • the dispersing polymeric material can be selected to be sufficiently non-reactive with the temperature regulating material so that a desired temperature stabilizing range is maintained when the temperature regulating material is dispersed within the dispersing polymeric material.
  • a dispersing polymeric material can include high-density polyethylenes having a melt index in the range of about 4 to about 36 g/10 min (e.g., high-density polyethylenes having melt indices of 4, 12, and 36 g/10 min, available from Sigma-Aldrich Corp., St. Louis, Mo.), modified forms of high-density polyethylenes (e.g., Fusabond® E MB100D, available from DuPont Inc., Wilmington, Del.), and modified forms of ethylene propylene rubber (e.g., Fusabond ® N MF416D, available from DuPont Inc., Wilmington, Del.).
  • high-density polyethylenes having a melt index in the range of about 4 to about 36 g/10 min e.g., high-density polyethylenes having melt indices of 4, 12, and 36 g/10 min, available from Sigma-Aldrich Corp., St. Louis, Mo.
  • modified forms of high-density polyethylenes
  • a melt index typically refers to a measure of the flow characteristics of a polymer (or a mixture of polymers) and typically inversely correlates with a molecular weight of the polymer (or the mixture of polymers).
  • the dispersing polymeric material can include a polar polymer (or a mixture of polar polymers) to facilitate dispersion of the polar phase change materials.
  • the dispersing polymeric material can include copolymers of polyesters, such as polybutylene terephthalate-block-polytetramethylene glycols (e.g., Hytrel® 3078, 5544, and 8238, available from DuPont Inc., Wilmington, Del.), and copolymers of polyamides, such as polyamide-block-polyethers (e.g., Pebax® 2533, 4033, 5533, 7033, MX 1205, and MH 1657, available from ATOFINA Chemicals, Inc., Philadelphia, Pa.).
  • polyesters such as polybutylene terephthalate-block-polytetramethylene glycols (e.g., Hytrel® 3078, 5544, and 8238, available from DuPont Inc., Wilmington, Del.)
  • polyamides such as polyamide-block-polyethers (e.g., Pebax® 2533, 4033, 5533, 7033, MX 1205, and MH
  • a dispersing polymeric material can have a slight or partial compatibility or miscibility with or affinity for a temperature regulating material (e.g., a semi-miscible polymer).
  • a temperature regulating material e.g., a semi-miscible polymer.
  • Such partial affinity can be adequate to facilitate dispersion of the temperature regulating material and to facilitate processing at higher temperatures.
  • this partial affinity can allow the temperature regulating material to separate out.
  • this partial affinity can lead to insolubilization of the phase change material and increased phase change material domain formation within the polymeric composite.
  • domain formation can lead to an improved thermal regulating property by facilitating transition of the phase change material between two states.
  • domain formation can serve to reduce or prevent loss or leakage of the phase change material from the polymeric composite during processing or during use.
  • phase change materials such as paraffinic hydrocarbons can be compatible with polyolefins or copolymers of polyolefins at lower concentrations of the phase change materials or when the temperature is above a critical solution temperature.
  • mixing of a paraffinic hydrocarbon (or a mixture of paraffinic hydrocarbons) and polyethylene or polyethylene-co-vinyl acetate can be achieved at higher temperatures and higher concentrations of the paraffinic hydrocarbon to produce a homogenous blend that can be easily controlled, pumped, and processed to form a polymeric composite. Once the polymeric composite has been formed and has cooled, the paraffinic hydrocarbon can become insoluble and can separate out into distinct domains.
  • the polyethylene-co-vinyl acetate can have between about 5 and about 90 percent by weight of the vinyl acetate, and, according to other embodiments of the invention, the vinyl acetate content is between about 5 and about 50 percent by weight. In one embodiment, the vinyl acetate content is desirably between about 18 to about 25 percent by weight. This content of vinyl acetate can allow for temperature miscibility control when mixing the paraffinic hydrocarbon and the polyethylene-co-vinyl acetate to form a blend.
  • this vinyl acetate content can allow for excellent miscibility at higher temperatures, thus facilitating melt spinning process stability and control due to homogeneity of the blend.
  • the polyethylene-co-vinyl acetate is semi-miscible with the paraffinic hydrocarbon, thus allowing for separation and domain formation of the paraffinic hydrocarbon.
  • a dispersing polymeric material can be selected to be compatible or miscible with or have an affinity for a matrix polymeric material.
  • the dispersing polymeric material can serve as a compatibilizing link between a temperature regulating material and the matrix polymeric material to thereby facilitate incorporating the temperature regulating material in a polymeric composite.
  • a dispersing polymeric material will include a thermoplastic polymer (or a mixture of thermoplastic polymers) (i.e., one that can be heated to form a melt and subsequently shaped or molded to form a polymeric composite).
  • the dispersing polymeric material desirably includes one or more low molecular weight polymers.
  • a low molecular weight polymer typically has a low viscosity when heated to form a melt, which low viscosity can facilitate dispersion of a temperature regulating material in the melt.
  • some polymers can be provided in a variety of forms having different molecular weights.
  • the term “low molecular weight polymer” can refer to a low molecular weight form of a polymer (e.g., a low molecular weight form of a polymer discussed herein).
  • a polyethylene having a number average molecular weight of about 20,000 (or less) can be used as a low molecular weight polymer in an embodiment of the invention.
  • a molecular weight or a range of molecular weights associated with a low molecular weight polymer can depend on the particular polymer selected (e.g., polyethylene) or on the method or equipment used to mix a temperature regulating material with the low molecular weight polymer.
  • a dispersing polymeric material can include a polymer (or a mixture of polymers) having a variety of chain structures that include one or more types of monomer units.
  • the dispersing polymeric material can include a linear polymer, a branched polymer (e.g., star branched polymer, comb branched polymer, or dendritic branched polymer), or a mixture thereof.
  • the dispersing polymeric material can include a homopolymer, a copolymer (e.g., terpolymer, statistical copolymer, random copolymer, alternating copolymer, periodic copolymer, block copolymer, radial copolymer, or graft copolymer), or a mixture thereof.
  • the reactivity and functionality of a polymer can be altered by addition of a functional group, such as amine, amide, carboxyl, hydroxyl, ester, ether, epoxy, anhydride, isocyanate, silane, ketone, and aldehyde.
  • the dispersing polymeric material can include a polymer capable of crosslinking, entanglement, or hydrogen bonding in order to increase its toughness or its resistance to heat, moisture, or chemicals.
  • dispersing polymeric materials include polyamides (e.g., Nylon 6, Nylon 6/6, Nylon 12, polyaspartic acid, polyglutamic acid, and so forth), polyamines, polyimides, polyacrylics (e.g., polyacrylamide, polyacrylonitrile, esters of methacrylic acid and acrylic acid, and so forth), polycarbonates (e.g., polybisphenol A carbonate, polypropylene carbonate, and so forth), polydienes (e.g., polybutadiene, polyisoprene, polynorbornene, and so forth), polyepoxides, polyesters (e.g., polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polycaprolactone, polyglycolide, polylactide, polyhydroxybutyrate, polyhydroxyvalerate, polyethylene adipate, polybutylene adipate, polypropylene succinate, and so forth), polyethers (e.
  • a polymeric composite can include up to about 100 percent by weight of a dispersing polymeric material. In some embodiments, a polymeric composite can include from about 10 percent to about 30 percent by weight of a dispersing polymeric material. And, according to one embodiment, a polymeric composite can include about 15 percent by weight of a dispersing polymeric material.
  • a matrix polymeric material can include any polymer (or mixture of polymers) that has or provides one or more desired physical properties for a polymeric composite or an article (e.g., a synthetic fiber) made therefrom.
  • physical properties include mechanical properties (e.g., ductility, tensile strength, and hardness), thermal properties (e.g., thermoformability), and chemical properties (e.g., reactivity).
  • the matrix polymeric material can be compatible or miscible with or have an affinity for a dispersing polymeric material.
  • such affinity can depend on, for example, similarity of solubility parameters, polarities, hydrophobic characteristics, or hydrophilic characteristics of the dispersing polymeric material and the matrix polymeric material.
  • affinity can facilitate forming a blend of the matrix polymeric material, the dispersing polymeric material, and a temperature regulating material during manufacture of the polymeric composite and, thus, ultimately can facilitate incorporation of more uniform or greater amounts or loading level of a phase change material in the polymeric composite.
  • the dispersing polymeric material can serve as a compatibilizing link between the matrix polymeric material and the temperature regulating material to thereby facilitate incorporating the temperature regulating material in the polymeric composite.
  • a matrix polymeric material can be selected to be compatible or miscible with or have an affinity for a temperature regulating material.
  • the matrix polymeric material can be selected for its affinity for the containment structure in conjunction with, or as an alternative to, its affinity for the phase change material.
  • the matrix polymeric material can have a slight or partial compatibility or miscibility with or affinity for the temperature regulating material.
  • Such partial affinity can be adequate to facilitate dispersion of the temperature regulating material and to facilitate processing at higher temperatures. At lower temperatures and shear conditions and once a polymeric composite has been formed, this partial affinity can allow the temperature regulating material to separate out.
  • this partial affinity can lead to insolubilization of the phase change material and increased phase change material domain formation within the polymeric composite.
  • a matrix polymeric material will include a thermoplastic polymer (or a mixture of thermoplastic polymers).
  • the matrix polymeric material desirably includes one or more high molecular weight polymers.
  • a high molecular weight polymer typically has enhanced physical properties (e.g., mechanical properties) but may have a high viscosity when heated to form a melt.
  • some polymers can be provided in a variety of forms having different molecular weights. Accordingly, as used herein, the term “high molecular weight polymer” can refer to a high molecular weight form of a polymer (e.g., a high molecular weight form of a polymer discussed herein).
  • a polyester having a number average molecular weight of about 20,000 (or more) can be used as a high molecular weight polymer in an embodiment of the invention. It should be recognized that a molecular weight or a range of molecular weights associated with a high molecular weight polymer can depend on the particular polymer selected (e.g., polyester) or on the method or equipment used to mix a temperature regulating material with the high molecular weight polymer.
  • a matrix polymeric material can include a polymer (or a mixture of polymers) having a variety of chain structures that include one or more types of monomer units.
  • the matrix polymeric material can include a linear polymer, a branched polymer (e.g., star branched polymer, comb branched polymer, or dendritic branched polymer), or a mixture thereof.
  • the matrix polymeric material can include a homopolymer, a copolymer (e.g., terpolymer, statistical copolymer, random copolymer, alternating copolymer, periodic copolymer, block copolymer, radial copolymer, or graft copolymer), or a mixture thereof.
  • a copolymer e.g., terpolymer, statistical copolymer, random copolymer, alternating copolymer, periodic copolymer, block copolymer, radial copolymer, or graft copolymer
  • the reactivity and functionality of a polymer can be altered by addition of a functional group, such as an amine, amide, carboxyl, hydroxyl, ester, ether, epoxy, anhydride, isocyanate, silane, ketone, and aldehyde, and the matrix polymeric material can include a polymer capable of crosslinking, entanglement, or hydrogen bonding in order to increase its toughness or its resistance to heat, moisture, or chemicals.
  • a functional group such as an amine, amide, carboxyl, hydroxyl, ester, ether, epoxy, anhydride, isocyanate, silane, ketone, and aldehyde
  • matrix polymeric materials include polyamides (e.g., Nylon 6, Nylon 6/6, Nylon 12, polyaspartic acid, polyglutamic acid, and so forth), polyamines, polyimides, polyacrylics (e.g., polyacrylamide, polyacrylonitrile, esters of methacrylic acid and acrylic acid, and so forth), polycarbonates (e.g., polybisphenol A carbonate, polypropylene carbonate, and so forth), polydienes (e.g., polybutadiene, polyisoprene, polynorbornene, and so forth), polyepoxides, polyesters (e.g., polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polycaprolactone, polyglycolide, polylactide, polyhydroxybutyrate, polyhydroxyvalerate, polyethylene adipate, polybutylene adipate, polypropylene succinate, and so forth), polyethers (e.g.,
  • a polymeric composite can include up to about 100 percent by weight of a matrix polymeric material. In some embodiments, a polymeric composite can include from about 40 percent to about 80 percent by weight of a matrix polymeric material. And, according to one embodiment, a polymeric composite can include about 70 percent by weight of a matrix polymeric material.
  • a polymeric composite in accordance with some embodiments of the invention can provide improved thermal regulating properties, which allow for an improved level of comfort when the polymeric composite is incorporated in articles such as apparel or footwear.
  • a polymeric composite in accordance with some embodiments of the invention can include a high loading level of one or more phase change materials within the polymeric composite. According to some embodiments of the invention, such high loading level can be provided because a dispersing polymeric material can facilitate incorporating a temperature regulating material in the polymeric composite.
  • a polymeric composite can also include a matrix polymeric material selected to improve the polymeric composite's overall physical properties (e.g., mechanical properties) and processability (e.g., by facilitating its formation as described herein).
  • a polymeric phase change material can provide adequate mechanical properties and can be used as a dispersing polymeric material, thus allowing for an even higher loading level and further improved thermal regulating properties.
  • a polymeric composite can have a latent heat that is at least about 2 J/g, such as at least about 10 J/g, at least about 20 J/g, at least about 30 J/g, at least about 40 J/g, at least about 50 J/g, or at least about 60 J/g.
  • the polymeric composite can have a latent heat ranging from about 2 J/g to about 200 J/g, such as from about 20 J/g to about 200 J/g, from about 40 J/g to about 200 J/g, or from about 60 J/g to about 200 J/g.
  • the temperature regulating material can include a phase change material and can further include a containment structure (e.g., microcapsules) to encapsulate, contain, surround, or absorb the phase change material.
  • a containment structure e.g., microcapsules
  • the dispersing polymeric material can include a low molecular weight polymer having an affinity for the containment structure or the phase change material
  • the matrix polymeric material can include a high molecular weight polymer having an affinity for the dispersing polymeric material and providing one or more desired physical properties to the polymeric composite or to an article made therefrom.
  • a polymeric phase change material can be used as the dispersing polymeric material, and the matrix polymeric material can be omitted for some embodiments of the invention.
  • the temperature regulating material is mixed with the dispersing polymeric material to form a first blend.
  • the dispersing polymeric material is melted to form a first melt, and the temperature regulating material is dispersed in the first melt to form the first blend.
  • a second blend is then formed using the first blend and the matrix polymeric material.
  • the first blend is processed to form granules, and the granules are mixed with the matrix polymeric material to form the second blend.
  • the matrix polymeric material can be melted to form a second melt, and the granules can be dispersed in the second melt to form the second blend.
  • the second blend can be formed by melting the granules and adding the matrix polymeric material thereto.
  • the granules need not be formed, and the first blend is mixed with the matrix polymeric material to form the second blend.
  • the second blend is processed to form the polymeric composite.
  • the second blend is processed to form pellets having enhanced reversible thermal properties provided by the phase change material incorporated therein.
  • FIG. 1 illustrates a manufacturing process for forming a polymeric composite in accordance with an embodiment of the invention.
  • a temperature regulating material is provided (step 10 ).
  • the temperature regulating material includes a phase change material and microcapsules that contain the phase change material.
  • the temperature regulating material can further include an amount of water wetting, coating, or absorbed by the microcapsules to form water-wetted microcapsules.
  • These water-wetted microcapsules can form a wet cake.
  • the wet cake can include from about 1 percent to about 90 percent by weight of the microcapsules and the phase change material with a remaining portion including water.
  • the wet cake includes from about 60 percent to about 70 percent by weight of the microcapsules and the phase change material with a remaining portion including water.
  • use of this wet cake can serve to facilitate handling of the microcapsules or can improve dispersion (e.g., prevent lumping) of the microcapsules in a melt.
  • phase change material in a raw form.
  • the phase change material in the raw form can be provided as a solid in a variety of forms (e.g., bulk form, powders, pellets, granules, flakes, and so forth) or as a liquid in a variety of forms (e.g., molten form, dissolved in a solvent, and so forth).
  • the dispersing polymeric material can include any polymer (or mixture of polymers) that facilitates incorporating the temperature regulating material in the polymeric composite.
  • the dispersing polymeric material includes a low molecular weight polymer having an affinity for the microcapsules. It should be recognized that the dispersing polymeric material can include one or more additional polymers (e.g., one or more additional low molecular weight polymers). It is also contemplated that the dispersing polymeric material can include a polymeric phase change material.
  • the temperature regulating material is mixed with the dispersing polymeric material to form a first blend (step 12 ).
  • the dispersing polymeric material is initially melted to form a first melt (e.g., in a heated mixing bowl or in a wet flushing apparatus), and the temperature regulating material (e.g., the wet cake) is added to and dispersed in the first melt to form the first blend.
  • Uniform dispersion of the microcapsules containing the phase change material in the first melt can be facilitated by the affinity of the dispersing polymeric material for the microcapsules.
  • dispersion can be facilitated by maintaining the dispersing polymeric material in a molten state or by mixing (e.g., agitation or stirring).
  • the water of the wet cake can be substantially removed by wet flushing.
  • the first blend can be heated until the water of the wet cake is substantially eliminated such that, for example, the first blend includes less than about 1 percent by weight of water.
  • step 12 can alternatively include dry blending the temperature regulating material with the dispersing polymeric material to form a dry blend, which can be subsequently heated to form the first blend.
  • the first blend is processed to form granules (steps 14 and 15 ).
  • the first blend is cooled to form a first solid (step 14 ), and the first solid is granulated to form the granules (step 15 ).
  • the first blend is extruded, for example, into a thread (or threads), which thread is cooled and subsequently granulated to form the granules. Extrusion can be performed using any extruder (including any conventional extruder such as a single screw extruder) to form a thread having a variety of regular or irregular cross sectional shapes.
  • any method can be used to granulate the first solid.
  • the first solid can be pulverized, cut, or chopped using any conventional method to form the granules.
  • the granules can be formed with a variety of shapes (e.g., spherical, ellipsoidal, cylindrical, powdered form, irregularly shaped, and so forth) and sizes.
  • the granules can have the same or different shapes or sizes and can be formed with smooth or rough surfaces.
  • the granules can have a maximum linear dimension (e.g., length or diameter) ranging from about 0.01 to about 10 millimeters and typically from about 1 to about 5 millimeters.
  • the granules can include from about 30 percent to about 60 percent by weight of the temperature regulating material (e.g., by dry weight of the microcapsules and the phase change material dispersed therein) with a remaining portion including the dispersing polymeric material.
  • the granules typically include from about 45 percent to about 55 percent by weight of the microcapsules and the phase change material with a remaining portion including the dispersing polymeric material.
  • the granules can also include a small amount of water (e.g., less than about 1 percent by weight of water).
  • the matrix polymeric material can include any polymer (or mixture of polymers) that provides one or more desired physical properties for the polymeric composite or for an article made therefrom.
  • the matrix polymeric material includes a high molecular weight polymer having an affinity for the dispersing polymeric material and providing desired physical properties, such as desired mechanical or thermal properties.
  • the matrix polymeric material can include one or more additional polymers (e.g., one or more additional high molecular weight polymers). It is also contemplated that the matrix polymeric material can be omitted for some embodiments of the invention.
  • the granules formed from step 15 are mixed with the matrix polymeric material to form a second blend (step 17 ).
  • the matrix polymeric material is initially melted to form a second melt, and the granules are added to and dispersed in the second melt to form the second blend. Dispersion of the granules in the second melt can be facilitated by the affinity of the matrix polymeric material for the dispersing polymeric material.
  • the granules typically melt after being added to the second melt to release the microcapsules containing the phase change material, and uniform dispersion of the microcapsules in the second melt can be facilitated by the affinity of the matrix polymeric material for the dispersing polymeric material and the affinity of the dispersing polymeric material for the microcapsules. Dispersion can also be facilitated by maintaining the matrix polymeric material in a molten state or by mixing (e.g., agitation or stirring). In the present embodiment, the water of the wet cake can be further removed by wet flushing. It should be recognized that step 17 can alternatively include dry blending the granules with the matrix polymeric material to form a dry blend, which can be subsequently heated to form the second blend.
  • the second blend is processed to form the polymeric composite (steps 20 and 21 ).
  • the polymeric composite can be formed in a variety of shapes, such as pellets, fibers, flakes, sheets, films, rods, and so forth.
  • the second blend is cooled to form a second solid (step 20 ), and the second solid is granulated to form pellets (step 21 ).
  • the second blend is extruded, for example, into a thread (or threads), which thread is cooled and subsequently granulated to form the pellets. Extrusion can be performed using any extruder (including any conventional extruder such as a single screw extruder) to form a thread having a variety of regular or irregular cross sectional shapes.
  • any method can be used to granulate the second solid.
  • the second solid can be pulverized, cut, or chopped using any conventional method to form the pellets.
  • the pellets can be formed with a variety of shapes (e.g., spherical, ellipsoidal, cylindrical, powdered form, irregularly shaped, and so forth) and sizes.
  • the pellets can have the same or different shapes or sizes and can be formed with smooth or rough surfaces.
  • the pellets can have a maximum linear dimension (e.g., length or diameter) ranging from about 1 to about 10 millimeters and typically from about 1 to about 5 millimeters.
  • the formed pellets typically include from about 10 percent to about 30 percent by weight of the temperature regulating material (e.g., the microcapsules and the phase change material), from about 10 percent to about 30 percent by weight of the dispersing polymeric material, and from about 40 percent to about 80 percent by weight of the matrix polymeric material.
  • the pellets can include an amount of water that is typically less than about 1 percent by weight.
  • the pellets can be used to form a variety of articles having enhanced reversible thermal properties, such as synthetic fibers, films, and injection molded articles.
  • FIG. 2 illustrates a manufacturing process to form a polymeric composite in accordance with another embodiment of the invention.
  • a temperature regulating material As with the previous embodiment, a temperature regulating material, a dispersing polymeric material, and a matrix polymeric material are provided (steps 30 - 32 ).
  • a polymeric phase change material can be used as the dispersing polymeric material, and the matrix polymeric material can be omitted for some embodiments of the invention.
  • the temperature regulating material, the dispersing polymeric material, and the matrix polymeric material are then mixed together (step 33 ).
  • the dispersing polymeric material is initially melted to form a first melt, and the temperature regulating material is added to and dispersed in the first melt to form a first blend. If present, water can be substantially removed by wet flushing.
  • the temperature regulating material can alternatively be dry blended with the dispersing polymeric material to form a dry blend, which can be subsequently heated to form the first blend.
  • the first blend is mixed with the matrix polymeric material to form a second blend.
  • the matrix polymeric material can be initially melted to form a second melt, and the first blend can be mixed with the second melt to form the second blend.
  • the matrix polymeric material can be added to and dispersed in the first blend to form the second blend.
  • the temperature regulating material, the dispersing polymeric material, and the matrix polymeric material can be mixed together using a variety of other methods to form the second blend.
  • a polymeric blend of the dispersing polymeric material and the matrix polymeric material can be formed, and the temperature regulating material can be subsequently added to and dispersed in the polymeric blend to form the second blend.
  • the temperature regulating material, the dispersing polymeric material, and the matrix polymeric material can be dry blended to form a dry blend, which can be subsequently heated to form the second blend.
  • the temperature regulating material, the dispersing polymeric material, and the matrix polymeric material can be provided together, heated, and mixed to form the second blend.
  • the temperature regulating material, the dispersing polymeric material, and the matrix polymeric material can be fed into an extruder to form the second blend, according to some embodiments of the invention.
  • the second blend is processed to form the polymeric composite (steps 35 and 36 ).
  • the polymeric composite can be formed in a variety of shapes, such as pellets, fibers, flakes, sheets, films, rods, and so forth.
  • the second blend is cooled to form a solid (step 35 ), and the solid is granulated to form pellets (step 36 ).
  • the second blend is extruded, for example, into a thread (or threads), which thread is cooled and subsequently granulated to form the pellets.
  • a multistage extruder is typically understood to include two or more extruder units that can be operatively connected in a variety of configurations (e.g., in series), wherein each extruder unit can be a single or multiple screw extruder, can have one or more inlet openings to receive a substance to be extruded, and can have one or more discharge ports to vent gases such as air, water (e.g., steam), and volatile materials.
  • a temperature regulating material and a dispersing polymeric material are provided (steps 40 and 41 ) and are fed into the multistage extruder 43 .
  • a polymeric phase change material can be used as the dispersing polymeric material for some embodiments of the invention.
  • the temperature regulating material and the dispersing polymeric material can be fed into the same inlet opening or different inlet openings of the multistage extruder 43 .
  • the temperature regulating material is mixed with the dispersing polymeric material to form a first blend, and the first blend is advanced through the multistage extruder 43 along a melt stream path 44 .
  • a matrix polymeric material is provided (step 42 ) and is fed into the multistage extruder 43 .
  • the matrix polymeric material can be omitted for some embodiments of the invention.
  • the matrix polymeric material is fed into an inlet opening downstream along the melt stream path 44 .
  • the matrix polymeric material can be fed into an inlet opening upstream along the melt stream path 44 (e.g., the same inlet opening used to receive the temperature regulating material or the dispersing polymeric material).
  • the first blend is mixed with the matrix polymeric material to form a second blend. As shown in FIG. 3 , water, if present, can be substantially removed through a discharge port (step 45 ).
  • the second blend is processed to form the polymeric composite (step 46 ).
  • the polymeric composite can be formed in a variety of shapes, such as pellets, fibers, flakes, sheets, films, rods, and so forth.
  • the second blend can be extruded through a die into a thread (or threads), which thread is cooled and subsequently granulated to form pellets.
  • the second blend can be extruded through a spinneret to form synthetic fibers.
  • phase change material in the raw form can be provided as a solid in a variety of forms (e.g., bulk form, powders, pellets, granules, flakes, and so forth) or as a liquid in a variety of forms (e.g., molten form, dissolved in a solvent, and so forth) (e.g., at step 10 of FIG. 1 , at step 30 of FIG.
  • a phase change material in a raw form is incorporated into a polymeric composite, wherein the phase change material can be contained within one or more isolated volumes or spaces that are dispersed throughout the polymeric composite.
  • a polymeric phase change material can be used as a dispersing polymeric material, and the polymeric phase change material can be used in a raw form.
  • a phase change material in a raw form can be introduced at virtually any time during a manufacturing process to form a polymeric composite (e.g., at virtually any of the steps illustrated in FIG. 1 , FIG. 2 , and FIG. 3 ).
  • a phase change material can be introduced via liquid injection or by feeding the phase change material in a solid form alone or in conjunction with a dispersing polymeric material or a matrix polymeric material.
  • a phase change material in a raw liquid form can be filtered or mixed to insure homogeneity prior to liquid injection.
  • a phase change material in a raw solid form can be fed into a feed throat of an extruder or can be side stuffed into the extruder in order to prevent feed throat plugging.
  • a phase change material in a raw form is desirably introduced at a later time during a manufacturing process to thereby ensure adequate dispersion of the phase change material or to reduce its exposure to manufacturing conditions (e.g., high temperature or shear forces) associated with forming a polymeric composite.
  • manufacturing conditions e.g., high temperature or shear forces
  • a polymeric composite in accordance with some embodiments of the invention can include a temperature regulating material and either a dispersing polymeric material or a matrix polymeric material. Either the dispersing polymeric material or the matrix polymeric material can be selected to have an affinity for (or a slight or partial affinity for) the temperature regulating material.
  • the polymeric composite can include the temperature regulating material and the matrix polymeric material that desirably includes one or more high molecular weight polymers. In forming the polymeric composite, the temperature regulating material and either the dispersing polymeric material or the matrix polymeric material can be mixed to form a blend, and the blend can then be processed to form the polymeric composite.
  • pellets formed in accordance with some embodiments of the invention can be used to form synthetic fibers, for injection molding processes, or for extrusion processes.
  • the pellets can be used in a melt spinning process to form synthetic fibers including, for example, from about 10 percent to about 30 percent by weight of a temperature regulating material.
  • the synthetic fibers can be collected into a strand or cut into staple fibers.
  • the synthetic fibers can be used to make woven or non-woven fabrics, or, alternatively, the synthetic fibers can be wound into a yarn to be used thereafter in a weaving or a knitting process to form a synthetic fabric.
  • the pellets can be mixed with one or more polymers (e.g., one or more thermoplastic polymers) to form a blend, which one or more polymers can be the same as or different from polymer(s) included in the pellets.
  • the resulting blend can then be processed to form synthetic fibers including, for example, from about 5 percent to about 10 percent by weight of the temperature regulating material.
  • one or more thermoplastic polymers can be used in conjunction with the pellets to form multi-component melt spun fibers (e.g., bi-component fibers), multi-component extruded films, multi-component injection molded products, and so forth.
  • a low molecular weight polyethylene homopolymer (AC-16 polyethylene, drop point of 102° C., manufactured by Honeywell Specialty Chemical) was added to a wet flushing apparatus, and the homopolymer was then slowly melted and mixed at about 110° C. to about 130° C. Once the homopolymer was melted, about 8.47 pounds of a wet cake was slowly added to the molten homopolymer over about a 30 minute time period to form a first blend.
  • the wet cake included water-wetted microcapsules containing a phase change material (micro PCM lot# M 42-31, 59.0 percent by weight of the microcapsules and the phase change material, manufactured by MicroTek Laboratories, Inc.).
  • the resulting first blend was then cooled to form a first solid, and the first solid was chopped to form a chopped material for further processing.
  • the chopped material included about 50 percent by weight of the microcapsules and the phase change material.
  • a dry blend was then formed by dry blending about 30 pounds of the chopped material with about 70 pounds of a high molecular weight fiber-grade polypropylene thermoplastic polymer (Polypropylene homopolymer 6852 from PB Amoco Polymers).
  • the resulting dry blend was then extruded using a 21 ⁇ 2 inch single screw extruder with all zones set at about 230° C., with a screw speed of about 70 rpm, with 150 mesh screens, and with a nitrogen purge, thus producing pellets.
  • the pellets were then oven dried overnight at about 50° C. and at about 1 mm Hg of vacuum.
  • the pellets including about 15 percent by weight of the microcapsules and the phase change material, were then extruded/melt spun at temperatures between about 230° C. and 265° C. (e.g., between about 235° C. to 245° C.).
  • Synthetic fibers were spun/wound at take-up speeds of up to about 1600 meters per minute (mpm) to yield from about 20 to about 6 deniers per fiber, and the synthetic fibers exhibited enhanced reversible thermal properties provided by the phase change material as discussed in Example 2.
  • DSC Differential Scanning Calorimeter
  • Test samples were prepared in Perkin Elmer hermetically sealed aluminum sample pans, and testing was performed while the test samples were continuously subjected to N 2 flow.
  • Test conditions included: 1) cooling the test samples to about ⁇ 10° C.; 2) isothermal hold for about 1 minute at ⁇ 10° C.; 3) heating from ⁇ 10° C. to about 50° C. at a rate of about 5° C. per minute; 4) isothermal hold for about 1 minute at 50° C.; and then 5) cooling from 50° C. to about ⁇ 10° C. at a rate of about 5° C. per minute.
  • the synthetic fibers provided between about 17.5 and 23.2 J/g of thermal energy storage capacity (i.e., latent heat).
  • phase change material in a raw form Kenwax 19 paraffin, blend of C18 through C24 paraffinic hydrocarbons, 150 J/g latent heat
  • a polymeric material Elvax 450, 18 percent by weight of vinyl acetate, polyethylene-co-vinyl acetate polymer supplied by DuPont Inc.
  • the phase change material and the polymeric material were mixed together at between 120° C. to 130° C. by hand to produce a 50:50 by weight blend that was homogeneous and clear.

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US11/078,656 US20050208286A1 (en) 2000-09-21 2005-03-11 Polymeric composites having enhanced reversible thermal properties and methods of forming thereof
KR1020077023012A KR101396006B1 (ko) 2005-03-11 2006-02-23 강화된 가역적 열 특성이 있는 중합체 복합재 및 그의 제조방법
KR1020137027992A KR101455562B1 (ko) 2005-03-11 2006-02-23 강화된 가역적 열 특성이 있는 중합체 복합재 및 그의 제조 방법
KR1020147016979A KR101563177B1 (ko) 2005-03-11 2006-02-23 강화된 가역적 열 특성이 있는 중합체 복합재 및 그의 제조 방법
EP20060735750 EP1856317B8 (en) 2005-03-11 2006-02-23 Polymeric composites having enhanced reversible thermal properties and methods of forming thereof
JP2008500731A JP2008533238A (ja) 2005-03-11 2006-02-23 高度な可逆の熱的性質を有する高分子複合体およびその形成方法
EP10182697.2A EP2392712B1 (en) 2005-03-11 2006-02-23 Polymeric composites having enhanced reversible thermal properties and methods of forming thereof
CN2006800077276A CN101208465B (zh) 2005-03-11 2006-02-23 具有提高的可逆热性能的聚合物复合材料及其形成方法
PCT/US2006/006216 WO2006098851A2 (en) 2005-03-11 2006-02-23 Polymeric composites having enhanced reversible thermal properties and methods of forming thereof
CN201210440162.8A CN103061039B (zh) 2005-03-11 2006-02-23 具有提高的可逆热性能的聚合物复合材料及其形成方法
TW95108055A TWI439499B (zh) 2005-03-11 2006-03-10 具有提高之可逆的熱性質之聚合複合物及其形成方法
JP2013086016A JP2013163886A (ja) 2005-03-11 2013-04-16 高度な可逆の熱的性質を有する高分子複合体およびその形成方法
JP2014003397A JP5969519B2 (ja) 2005-03-11 2014-01-10 高度な可逆の熱的性質を有する高分子複合体およびその形成方法
US14/492,691 US20150018480A1 (en) 2000-09-21 2014-09-22 Polymeric composites having enhanced reversible thermal properties and methods of forming thereof
JP2015208052A JP6105701B2 (ja) 2005-03-11 2015-10-22 高度な可逆の熱的性質を有する高分子複合体およびその形成方法
JP2016047274A JP6208793B2 (ja) 2005-03-11 2016-03-10 高度な可逆の熱的性質を有する高分子複合体およびその形成方法

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