WO2022238862A1

WO2022238862A1 - Fibers with active additives technical field

Info

Publication number: WO2022238862A1
Application number: PCT/IB2022/054277
Authority: WO
Inventors: Melissa North; Anthony CASCIO
Original assignee: Aladdin Manufacturing Corporation
Priority date: 2021-05-12
Filing date: 2022-05-09
Publication date: 2022-11-17

Abstract

The present disclosure provides yams and multi-component fibers having a plurality of solid particles having active materials dispersed throughout a portion of the fibers, where at least a portion of the solid particles is disposed near, abutting, or exposed at a surface of the fiber.

Description

1

Fibers with active additives technical field

This disclosure relates to polymeric fibers having active components incorporated therein in the form of the plurality of solid particles. The disclosure also relates to yams and flooring products comprising the same.

BACKGROUND

Within the textile industry, and particularly the carpet industry, consumers increasingly demand products that have more robust characteristics and properties. Some of the properties of interest include antibacterial or antifungal, or antiviral properties. Other properties include high wear resistance and abrasion resistance. Yet other properties include the presence of unique colors, phosphorescence, fluorescence, and reflectivity.

Thus, there is a clear need for new products for use in textiles that exhibit such unique properties. Still, further, there is a need for methods of manufacturing such products. These needs and other needs are at least partially satisfied by the present disclosure. SUMMARY

The present disclosure is directed to a fiber comprising: a first component comprising a first polymer; and a plurality of solid particles dispersed within the first polymer, wherein at least a portion of the plurality of solid particles is situated near, abutting, or exposed at a surface of the fiber, and wherein the plurality of solid particles comprise an active component.

In still further aspects, the plurality of solid particles form a concentration gradient from the surface of the fiber to a bulk of the fiber. While in still further aspects, the at least a portion of the plurality of solid particles situated near, abutting, or exposed at the surface of the fiber is greater than a portion of the plurality of solid particles in a bulk of the fiber.

In still further aspects, also disclosed herein is a fiber comprising a second component comprising a second polymer. In such exemplary and unlimiting aspects, the fiber is a bicomponent fiber having a side-by-side configuration, core-sheath configuration, a segmented configuration, or an islands-in-the-sea configuration. 2

In yet still further aspects, the second polymer can be the same or different from the first polymer.

In yet still, further aspects disclosed herein is a yam comprising any of the disclosed herein fibers. In yet still, further aspects disclosed herein is a flooring product comprising any of the disclosed herein yarns.

Also disclosed herein is a method of forming any of the disclosed herein fibers. In such aspects, the method comprises extruding a first composition comprising a first polymer and a plurality of solid particles to form a first component. In yet other aspects, the method can further comprise extruding a second composition comprising a second polymer to form a second component.

Also disclosed herein is a method of making any of the disclosed herein yarns, wherein the method comprises steps of blending, carding, drawing out, twisting, spinning, or any combination thereof of any of the disclosed herein fibers. In yet other aspects, disclosed are also methods of making any of the disclosed herein flooring products comprising tufting any of the disclosed herein yards to form a face portion of the flooring products.

The details of one or more aspects of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Example features and aspects are disclosed in the accompanying drawings. However, the present disclosure is not limited to the precise arrangements shown, and the drawings are not necessarily drawn to scale. FIG. 1 illustrates a perspective view of an exemplary fiber in one aspect.

FIG. 2 illustrates a cross-sectional view along line II-II of the fiber of FIG.1.

FIG. 3 illustrates a perspective view of an exemplary fiber in one aspect.

FIG. 4 illustrates a cross-sectional view along line IV-IV of the fiber of FIG. 3. 3

FIG. 5 illustrates an alternative cross-sectional view of a fiber similar to FIG. 3.

FIG. 6A illustrates a radial cross-sectional view of a fiber according to one aspect.

FIG. 6B illustrates a radial cross-sectional view of a fiber according to another aspect. FIG. 7 illustrates a radial cross-sectional view of a fiber according to another aspect. FIG. 8 illustrates a radial cross-sectional view of a fiber according to another aspect. FIG. 9 illustrates a radial cross-sectional view of a fiber according to another aspect. FIG. 10 illustrates a radial cross-sectional view of a fiber according to another aspect. FIG. 11 illustrates a radial cross-sectional view of a fiber according to another aspect. FIG. 12 illustrates a radial cross-sectional view of a fiber according to another aspect. FIG. 13 illustrates a perspective view of an exemplary fiber in another aspect. DETAILED DESCRIPTION

The present invention can be understood more readily by referencing the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present articles, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific or exemplary aspects of articles, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein describes particular aspects only and is not intended to be limiting.

The following description of the invention is provided as an enabling teaching of the invention in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those of ordinary skill in the pertinent art will recognize that many modifications and adaptations to the present invention are possible and may even be desirable in certain circumstances and are a 4 part of the present invention. Thus, the following description is again provided as illustrative of the principles of the present invention and not in limitation thereof.

The compositions and methods of the appended claims are not limited in scope by the specific compositions and methods described herein, which are intended as illustrations of a few aspects of the claims, and any compositions and methods that are functionally equivalent are intended to fall within the scope of the claims. Various modifications of the compositions and methods in addition to those shown and described herein are intended to fall within the scope of the appended claims. Further, while only certain representative compositions and method steps disclosed herein are specifically described, other combinations of the compositions and method steps are also intended to fall within the scope of the appended claims, even if not specifically recited. Thus, a combination of steps, elements, components, or constituents may be explicitly mentioned herein; however, other combinations of steps, elements, components, and constituents are included, even though not explicitly stated. DEFINITIONS

The term "comprising" and variations thereof as used herein is used synonymously with the term "including" and variations thereof and are open, non-limiting terms. Although the terms "comprising" and "including" have been used herein to describe various aspects, the terms "consisting essentially of and "consisting of can be used in place of "comprising" and "including" to provide more specific aspects of the invention and are also described.

As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an "article" includes aspects having two or more such articles, or reference to a "product" includes aspects having two or more such products unless the context clearly indicates otherwise.

It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate aspects, can also be provided in combination in a single aspect. Conversely, various features of the disclosure, which are, for brevity, described 5 in the context of a single aspect, can also be provided separately or in any suitable subcombination.

For the terms "for example" and "such as," and grammatical equivalences thereof, the phrase "and without limitation" is understood to follow unless explicitly stated otherwise.

Other than in the examples, or where otherwise noted, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood at the very least and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, to be construed in light of the number of significant digits and ordinary rounding approaches. Throughout this disclosure, various aspects of the invention can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges and individual numerical values within that range. Thus, for example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any whole and partial increments therebetween. This applies regardless of the breadth of the range.

"Optional" and "optionally" means that the subsequently described event or circumstance may or may not occur and that the description includes instances where said event or circumstance occurs and instances where it does not.

As used herein, the term or phrase "effective," "effective amount," or "conditions effective to" refers to such amount or condition that is capable of performing the function or property for which an effective amount or condition is expressed. As will be pointed out below, the exact amount or particular condition required will vary from one aspect to another, depending on recognized variables such as the materials employed and the processing conditions observed. Thus, it is not always possible to specify an exact "effective amount" or "condition effective to." 6

It will be understood that, although the terms "first," "second," etc., may be used herein to describe various elements, components, regions, layers, and/or sections. These elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or a section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of example aspects.

As used herein, the term "substantially" means that the subsequently described event or circumstance completely occurs or that the subsequently described event or circumstance generally, typically, or approximately occurs.

Still further, the term "substantially" can in some aspects refer to at least about 80 %, at least about 85 %, at least about 90 %, at least about 91 %, at least about 92 %, at least about 93 %, at least about 94 %, at least about 95 %, at least about 96 %, at least about 97 %, at least about 98 %, at least about 99 %, or about 100 % of the stated property, component, composition, or other condition for which substantially is used to characterize or otherwise quantify an amount.

As used herein, the term "substantially," in, for example, the context "substantially identical" or "substantially similar" refers to a method or a product, or an article, or a system, or a component that is at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% similar to the method, product, article, system, or the component it is compared to.

As used herein, the term "composition" is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from a combination of the specified ingredients in the specified amounts.

A weight percent (wt.%) of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included. 7

The term "polymer" may comprise homopolymers, copolymers, such as, for example, block, graft, random, and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term "polymer" shall include all possible structural isomers; stereoisomers including, without limitation, geometric isomers, optical isomers, or enantiomers; and/or any chiral molecular configuration of such polymer or polymeric material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic configurations of such polymer or polymeric material. The term "polymer" shall also include polymers made from various catalyst systems, including, without limitation, the Ziegler-Natta catalyst system and the metallocene/singl e-site catalyst system.

The term "meltspun," as used herein, may comprise fibers that are formed by extruding molten thermoplastic material as fibers from a plurality of fine, usually circular or trilobal, die capillaries of a spinneret and solidifying the extruded fibers by cooling them as they emerge from the die capillaries.

The term "spunbond," as used herein, may comprise fibers that are formed by extruding molten thermoplastic material as fibers from a plurality of fine, usually circular or trilobal, capillaries of a spinneret with the diameter of the extruded fibers then being rapidly reduced. According to an embodiment of the invention, spunbond fibers are generally not tacky when they are deposited onto a collecting surface and may be generally continuous.

The term "meltblown," as used herein, may comprise fibers formed by extruding a molten thermoplastic material through a plurality of fine die capillaries as molten threads or fibers into converging high velocity, usually hot, gas (e.g., air) streams which attenuate the fibers of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter, according to certain aspects of the invention. According to an embodiment of the invention, the die capillaries may be circular. Thereafter, the meltblown fibers are carried by the high-velocity gas stream and are deposited on a collecting surface to form a web of randomly disbursed meltblown fibers. Meltblown fibers are microfibers that may be continuous or discontinuous and are generally tacky when deposited onto a collecting surface. 8

Any recited method can be carried out in the order of events recited or in any other order that is logically possible. That is, unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or description that the steps are to be limited to a specific order, it is in no way intended that an order be inferred in any respect. This holds for any possible non-express basis for interpretation, including matters of logic concerning the arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.

The present invention may be understood more readily by reference to the following detailed description of various aspects of the disclosure and the examples included therein and their previous and following description.

FIBERS, YARNS, AND FLOORING PRODUCTS

The present disclosure is directed to a fiber comprising a first component comprising a first polymer; and a plurality of solid particles dispersed within the first polymer. In still further aspects, the at least a portion of the plurality of solid particles is situated near, abutting, or exposed at a surface of the fiber. In yet further aspects, the plurality of solid particles comprise an active component.

Some exemplary fibers disclosed herein are shown in FIGs 1 and 2. FIG. 1 shows a perspective view of an exemplary and unlimiting fiber 100. The fiber 100 is defined by a surface 102 and a bulk of the fiber 104. In such exemplary and unlimiting aspects, the plurality of solid particles 106 are dispersed such that at least a portion of the particles 106 is positioned at or near the surface of the fiber 102. FIG. 2 shows a cross-section of the same fiber 200 having a surface 202 and a bulk 204. In such exemplary aspects, the plurality of solid particles 206 can be dispersed across the fiber, with at least a portion of the plurality of solid particles 206 being near or at the surface of the fiber 202.

In still further aspects, the plurality of solid particles can form a concentration gradient from the surface of the fiber to the bulk of the fiber. 9

In such exemplary aspects, the at least a portion of the plurality of solid particles concentrated situated near, abutting, or exposed at the surface of the fiber is greater than a portion of the plurality of solid particles in a bulk of the fiber.

In still further aspects, the active component in the plurality of solid particles can be any active component that can provide for the desired application. For example, and without limitations, in some aspects, the active component can comprise an antibacterial additive, an antifungal additive, an antiviral additive, or a bug resistant additive, an insecticide additive, or a combination thereof. Yet, in other aspects, the active component can be a component that can change the visual properties of the fiber. In yet other aspects, the active component can be a component that changes the physical properties of the fiber.

In still further aspects, the active material can comprise a copper-containing compound, a zinc-containing compound, a silver-containing compound, or a combination thereof. It is understood that such compounds can have antibacterial, antifungal, antiviral, insecticide, or bug resistant properties. In yet other aspects, the active components can further comprise biguanides, essential oils, pyrethroids, terpenes, acyclic sesquiterpenoids, or any combination thereof. It is understood that any of these compounds can be present with or without of the copper-containing compound, the zinc-containing compound, the silver-containing compound, or their combination. In yet further aspects, these active components can be present in any amount that is efficient to provide for the desired result. In such exemplary and unlimiting aspects, the desired result can be, for example, and without limitations providing the fiber with the resistance to microbes, viruses, fungi, insects, and the like.

In yet other aspects, the active components can be present in any form suitable for the manufacturing and delivery. In yet other materials, the active components can be encapsulated to provide a solid particle as desired. In aspects where the active components are encapsulated, it is understood that the encapsulation can be provided to allow controlled and/or slow release of the active components. In such aspects, any known in the art methods of encapsulation that are applicable to the specific application can be used. 10

In yet further aspects, when the active components are affecting the visual appearance of the fiber, this visual appears can be a unique color, phosphorescence, fluorescence, or reflectivity. In yet still further aspects, the active components can help maintain the desirable physical and mechanical properties of the fiber, such as strength, abrasion resistance, wear resistance, and the like.

It is understood, however, that the fiber can comprise any of the disclosed herein active components alone or in any combination depending on the desired application.

In still further aspects, the plurality of solid particles can further comprise mica particles. In some exemplary and unlimiting aspects, the mica particles can comprise ground mica, for example, wet-ground mica, which maintains the brilliance of the cleavage faces of the sheet material. In yet further aspects, the mica particles can comprise muscovite, paragonite, biotite, lepidolite, phlogopite, zinnwaldite, clintonite, hydro-muscovite, illite, phengite, or sericite, or any combination thereof.

In still further aspects, the plurality of solid particles can further comprise glass flakes, glass beads, or any combination thereof.

In certain aspects, the plurality of solid particles can also comprise a pigment or a dye. In some exemplary and unlimiting aspects, the pigment (or the dye) can be incorporated in the glass flakes or glass beads.

In certain aspects, the plurality of solid particles can provide a predetermined visual appearance to the fiber. For example, the visual appearance can comprise at least partial transparency, at least partial opacity, at least partial phosphorescence, at least partial fluorescence, at least partial light reflection, at least partial luster, or any combination thereof.

In certain aspects the fibers disclosed herein can have optical transparence from 40% to 100%, including exemplary value of 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%,

85%, 90%, 95%, 99%, and 99.99%.

In some exemplary aspects where the glass flakes or glass beads are present, these glass flakes or glass beads can comprise E-glass, C-glass, E-CR-glass, or combinations thereof. 11

It is understood that the term "E-glass" as used herein refers to alumino-borosilicate glass having less than 1%, less than 0.9%, less than 0.8%, less than 0.7%, less than 0.6%, less than 0.5%, less than 0.4%, less than 0.3%, less than 0.2%, or even less than 0.1% of alkali oxides by weight. Still further, the term "C-glass" as used herein refers to alkali-lime glass with a high boron oxide content. In yet other aspects, the term "E-CR- glass" as used herein refers to alumino-lime silicate glass with less than 1%, less than 0.9%, less than 0.8%, less than 0.7%, less than 0.6%, less than 0.5%, less than 0.4%, less than 0.3%, less than 0.2%, or even less than 0.1% of alkali oxides by weight.

In still further aspects where the plurality of solid particles comprise mica or glass flakes or glass beads, such particles can be treated with a coating. It is understood that in such exemplary aspects, the coating is applied to the particles prior to dispersing the same in the fiber. In certain exemplary and unlimiting aspects, the coating can reduce the abrasiveness of the plurality of solid particles. In certain aspects, the coating comprises a silane coating. In yet further exemplary and unlimiting aspects, the silane coating can comprise a silane coupling reagent. In such exemplary aspects, the silane coupling reagent can be selected from 3 -aminopropyltri ethoxy silane, vinyltrimethoxy silane, 3 -glycidoxypropyltrimethoxy silane, or 3- methacryloxypropyltrimethoxysilane, or a combination thereof.

Some additional aspects are disclosed in the U.S. Provisional Application No. 63/187,680, the content of which is incorporated herein in its whole entirety.

In still further aspects, the plurality of solid particles comprising any of the disclosed above active components can be present in any amount to provide for the desired results. In certain aspects, the plurality of solid particles can be present in an amount from 0.01 wt% to 5 wt%, including exemplary values of 0.05 wt%, 0.1 wt%, 0.5 wt%, 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, 4 wt%, and 4.5 wt% by weight base on the total weight of the fiber. In yet other aspects, the plurality of solid particles can be present in an amount between any two foregoing values.

In still further aspects, wherein the plurality of solid particles have a concentration of at least 1%, at least 5%, at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, or at least 80% by volume within the first polymer. 12

In some aspects, the plurality of solid particles can have any shape or form. In some aspects, the plurality of solid particles can be substantially spherical. However, in other aspects, the plurality of particles can have an irregular shape. In some aspects, the plurality of particles can have a prismatic shape, bladelike shape, or any combination thereof. In some aspects, the plurality of particles can have a plurality of edges and/or grains. In yet other aspects, the plurality of particles can have an elongated shape defined by an average length. In such exemplary aspects, the particles can have a length to a width ratio greater than 1, greater than 1.5, or greater than 2, greater than 3, greater than 4, or greater than 5. In yet other aspects, the plurality of particles can be defined by an average diameter. In still further aspects, the plurality of particles can be defined by an average thickness.

In still further aspects, the plurality of solid particles can have an average particle diameter from 0.5 micron to 50 microns, including exemplary values of 1 micron, 5 microns, 7 microns, 10 microns, 12 microns, 15 microns, 17 microns, 20 microns, 22 microns, 25 microns, 27 microns, 30 microns, 32 microns, 35 microns, 37 microns, 40 microns, 42 microns, 45 microns, and 47 microns.

In yet further aspects, the plurality of solid particles can have an average particle diameter of 1 micron, 2 microns, 3 microns, 4 microns, 5 microns, 6 microns, 7 microns, 8 microns, 9 microns, 10 microns, 11 microns, 12 microns, 13 microns, 14 microns, 15 microns, 16 microns, 17 microns, 18, microns, 19 microns, 20 microns, 21 microns, 22 microns, 23 microns, 24 microns, 25 microns, 26 microns, 27 microns, 28 microns, 29 microns, 30 microns, 31 microns, 32 microns, 33 microns, 34 microns, 35 microns, 36 microns, 37 microns, 38 microns, 39 microns, 40 microns, 41 microns, 42 microns, 43 microns, 44 microns, 45 microns, 46 microns, 47 microns, 48 microns, 49 microns, or 50 microns. In yet further aspects, the average particle diameter can have any value between any two foregoing values.

In yet further aspects, the plurality of solid particles can have an average particle length of 1 micron, 2 microns, 3 microns, 4 microns, 5 microns, 6 microns, 7 microns, 8 microns, 9 microns, 10 microns, 11 microns, 12 microns, 13 microns, 14 microns, 15 microns, 16 microns, 17 microns, 18, microns, 19 microns, 20 microns, 21 microns, 22 microns, 23 microns, 24 microns, 25 microns, 26 microns, 27 microns, 28 microns, 29 13 microns, 30 microns, 31 microns, 32 microns, 33 microns, 34 microns, 35 microns, 36 microns, 37 microns, 38 microns, 39 microns, 40 microns, 41 microns, 42 microns, 43 microns, 44 microns, 45 microns, 46 microns, 47 microns, 48 microns, 49 microns, or

50 microns. In yet further aspects, the average particle length can have any value between any two foregoing values

In still further aspects, when the plurality of fibers comprises glass flakes, for example, such flakes can have an average thickness ranging from 0.5 microns to 8 microns, for example 0.5 microns to 7 microns, 0.5 microns to 6 microns, 0.5 microns to 5 microns, 0.5 microns to 4 microns, 0.5 microns to 3 microns, 0.5 microns to 2 microns, 0.5 microns to 1 micron, 1 micron to 8 microns, 1 micron to 7 microns, 1 micron to 6 microns, 1 micron to 5 microns, 1 micron to 4 microns, 1 micron to 3 microns, 1 micron to 2 microns, 2 microns to 8 microns, 2 microns to 7 microns, 2 microns to 6 microns, 2 microns to 5 microns, 2 microns to 4 microns, 2 microns to 3 microns, 3 microns to 8 microns, 3 microns to 7 microns, 3 microns to 6 microns, 3 microns to 5 microns, 3 microns to 4 microns, 4 microns to 8 microns, 4 microns to 7 microns, 4 microns to 6 microns, 4 microns to 5 microns, 5 microns to 8 microns, 5 microns to 7 microns, 5 microns to 6 microns, 6 microns to 8 microns, 6 microns to 7 microns, or 7 microns to 8 microns. In other exemplary aspects, the glass flakes may have an average thickness of 0.5 microns, 0.6 microns, 0.7 microns, 0.8 microns, 0.9 microns, 1 micron, 1.2 microns, 1.4 microns, 1.6 microns, 1.8 microns, 2.0 microns, 2.2 microns, 2.4 microns, 2.6 microns, 2.8 microns, 3.0 microns, 3.2 microns, 3.4 microns, 3.6 microns, 3.8 microns, 4.0 microns, 4.2 microns, 4.4 microns, 4.6 microns, 4.8 microns, 5.0 microns, 5.2 microns, 5.4 microns, 5.6 microns, 5.8 microns, 6.0 microns, 6.2 microns, 6.4 microns, 6.6 microns, 6.8 microns, 7.0 microns, 7.2 microns, 7.4 microns, 7.6 microns, 7.8 microns, or 8.0 microns.

In some aspects, the glass flakes can comprise E-glass flakes having an average diameter ranging from 27 microns to 32 microns and an average thickness ranging from 0.9 microns to 1.3 microns. In other aspects, the glass flakes can comprise E-glass flakes having an average diameter ranging from 27 microns to 32 microns and an average thickness ranging from 3 microns to 7 microns. 14

In yet further exemplary aspects, the glass flakes can comprise C-glass flakes having an average diameter ranging from 20 microns to 50 microns and an average thickness ranging from 3 microns to 7 microns.

In some exemplary aspects, the glass flakes can comprise E-CR-glass flakes having an average diameter ranging from 27 microns to 32 microns and an average thickness ranging from 0.9 microns to 1.3 microns. In some aspects, the glass flakes comprise E- CR-glass flakes having an average diameter ranging from 8 microns to 12 microns and an average thickness ranging from 0.9 microns to 1.3 microns. In other aspects, the glass flakes can comprise E-CR-glass flakes having an average diameter ranging from 27 microns to 32 microns and an average thickness ranging from 2.3 microns to 3.3 microns. In still further aspects, the glass flakes can comprise E-CR-glass flakes having an average diameter ranging from 27 microns to 32 microns and an average thickness ranging from 4 microns to 6 microns.

It is understood, however, that the thickness ranges and their combinations with the average particles diameters are not limited to the glass flakes only. Any of the disclosed herein a plurality of solid particles can have the disclosed above average thickness and/or diameter where applicable.

In still further aspects, the fiber disclosed herein can comprise a second component comprising a second polymer. In such exemplary aspects, the fiber can be called a bicomponent fiber.

As used herein, the term "bicomponent fibers" are fibers that are formed by extrusion spinning. In such aspects, fibers having two components extruded from separate extruders but spun together to form one fiber. Bicomponent fibers are also sometimes referred to as conjugate fibers or multi-component fibers. In certain aspects, the first and the second polymers used to form the first and the second component of the bicomponent fiber can be the same or different.

In certain aspects, the same polymer is used to form the first and the second components to create the desired gradient of the plurality of solid particles between the surface of the fiber and the bulk of the fiber while keeping the same polymer 15 composition of the fiber. However, in other aspects, the first polymer and the second polymers can be different depending on the desired application.

The first and the second polymers, either the same or different, of the bicomponent fibers can be arranged in a substantially constant position in distinct zones across the cross-section of the bicomponent fibers and extend continuously along the length of the bicomponent fibers. The configuration of such a bicomponent fiber can be, for example, a sheath/core arrangement wherein one polymer is surrounded by another, or can be a side-by-side arrangement, a homo-homo arrangement, a pie arrangement, or an "islands-in-the-sea" arrangement, each as is known in the art of multi-component, including bicomponent, fibers. In yet other aspects, the bicomponent fiber can have a core/sheath configuration. In some aspects, for example, where the first polymer and the second polymer are not the same, a core fiber can be made from the second polymer encased within a thermoplastic sheath made from the first polymer or have a side-by- side arrangement of different thermoplastic fibers. In such exemplary and unlimiting aspects, the first and the second polymers can melt at different temperatures. In the exemplary sheath/core arrangement, these bicomponent fibers can provide thermal bonding due to the melting of the sheath polymer while retaining the desirable strength characteristics of the core polymer.

As disclosed above, the disclosed herein bicomponent fibers can have a core-sheath configuration. In such aspects, the core can comprise the second component as disclosed herein, and the sheath can comprise the disclosed herein first component.

In yet other exemplary aspects, the disclosed herein bicomponent fiber can have a segmented configuration. In such an exemplary segmented configuration, the at least one of the segments can comprise the disclosed herein first component.

In still further aspects, the second polymer can comprise a further plurality of solid particles. In some aspects, the further plurality of solid particles is the same or different from the plurality of solid particles present in the first component. In yet other aspects, the second polymer is substantially free of any plurality of solid particles. Some exemplary bicomponent fibers are shown in FIGS. 3-5. FIG. 3 shows an exemplary bicomponent fiber 300, having the first component 302 present as a sheath and the 16 second component 304 present as a core. In this exemplary and unlimiting aspect, the plurality of solid particles 310 are disposed near or at the surface of the fiber 306. FIG. 3 further shows that the bulk of the sheath 308 can have fewer particles than the surface of the fiber 306. Again it is understood that the illustrated fiber is only exemplary and unlimiting.

FIGS.4 and 5 show a cross-section of the exemplary core-sheath bicomponent fiber. In FIG. 4, the bicomponent fiber 400 has a first component 402 as a sheath and a second component 404 as a core. In this exemplary fiber, the second component is substantially free of any plurality of solid particles, while the first component 402 has a plurality of solid particles 410 wherein at least a portion of them is disposed near or at a surface of the fiber 406 and at least a portion of the particles can also be dispersed in a bulk of the sheath 408. It is understood that in some aspects, there can be a concentration gradient between the amount of particles disposed near or at the surface of the fiber and the amount of particles disposed in the bulk of the fiber, or as shown in the bulk of the sheath of the fiber. In some aspects, the amount of solid particles disposed near and/or at the surface of the fiber can be greater than the amount of solid particles disposed in the sheath of the fiber.

FIG. 5 shows an exemplary fiber 500, where both the first component 502 that forms the sheath and the second component 504 that forms the core has a plurality of solid particles 512, 514. As discussed above, the plurality of solid particles 512 in the first component 502 and the plurality of solid particles 514 in the second component 504 can be the same or different. It is understood that the difference can be in the size of the particles and/or type and/or composition of the solid particles. In still further aspects, the plurality of solid particles 512 can be disposed near and/or at the surface of the fiber 506 or in bulk 508. The particles 514 can also be disposed in the core bulk 510.

In still further aspects, the first component in the bicomponent fiber can define at least 1%, at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the total surface of the fiber. 17

In yet further aspects, the fibers disclosed herein can be multi-component. In such aspects, a third or more components can be present. In such exemplary aspects, the third or more components can be the same as the first component and/or the second component or different from them.

In still further aspects, a radial cross-sectional shape of the multi-component (or bi component) fibers described herein can be round or can have other shapes, such as octalobal, delta, sunburst (also known as sol), scalloped oval, trilobal, tetra-channel (also known as quatra-channel), kidney, scalloped ribbon, ribbon, starburst, semi circular, and the like. The radial cross-sectional shape refers to the shape of the fiber as viewed in a plane that extends perpendicular to a central axis of the fiber (e.g., an end view of the fiber). In still further aspects, the fibers disclosed herein can be solid, hollow, or multi-hollow (e.g., defining one or more axial voids therethrough).

In still further aspects, the fibers disclosed herein can have a plurality of solid particles and/or a further plurality of solid particles, if present, to have a particle size comparable to the overall physical size of the first component and/or the second component. For example, a size of the plurality of solid particles and/or the further plurality of solid particles, if present, is substantially comparable to one of i) a cross- sectional size of the first component, ii) a cross-sectional size of the second component, or iii) a cross-sectional size of the fiber.

A radial cross-sectional view of additional exemplary fibers is shown in FIGS.6A-12, where the first and the second components have different arrangements with respect to each other. As shown, the first component comprises the first polymer and the plurality of solid particles dispersed therein, and the second component comprises the second polymer, wherein the second component can comprise the further plurality of solid particles or be substantially free of any particles.

FIGS. 6 A and 6B illustrate a multi-component fiber 600 having a trilobal radial cross- sectional shape and includes the first component 602 and the second component 608. In this exemplary aspect, the second component 608 forms a core and is fully encapsulated by the first component 602. The first component 602 and the second component 608 define trilobal radial cross-sectional shaped fibers. The first component 18

602 includes the plurality of solid particles 610 dispersed near or at the outmost surface of the multi-component fiber and also can have a plurality of solid particles 610 dispersed within the bulk 606 of the first component 602. FIG. 6B, however, shows that the plurality of solid particles 610 are only dispersed around the lobes of the first component 602 and the portions of the surface where the only second component 608 is present are substantially free of any plurality of solid particles. In such exemplary aspects, the second component 608 is not fully encapsulated by the first component 602. Again, it is understood that if the particles are present both in the first and the second components, they can have the same or different size, type, or composition. FIG. 7 illustrates a multi-component fiber 700 that also has a trilobal radial cross- section shape. In this aspect, the first component 702, has a larger portion of the fiber and does not fully encapsulate the second component 704. In this example, the second component 704 defined a circular radial cross-sectional shaped fiber being substantially free of the plurality of particle and the first component 702 having the plurality of solid particles 706 dispersed therein. The first component 702 defines a radial cross-sectional shape that is substantially similar to an individual lobe of a trilobal fiber, and strands of the first component 702 are coupled to various portions of the second component 704.

As another example, in the multi-component fiber 800 shown in FIG. 8, the first component 802 and the second component 804 have a semi-circular shaped radial cross-section with a circular shaped axial void 808 that is centered within the fiber 800. In this exemplary aspect, the first component 802 and the second component 804 are coupled together along flat surfaces of each component 802, 804 along a plane that includes the central axis of the fiber 800. In such exemplary aspects, an external surface of the fiber 800 has a circular radial cross-sectional shape. The first component 802 includes the first polymer and the plurality of solid particles 806 dispersed within it, with at least a portion of the plurality of solid particles located near and/or at the surface of the fiber. The second component 804 can be substantially free of the plurality of solid particles. However, in other aspects not shown herein, the second component 804 can also comprise a further plurality of solid particles that can be the same or different from the particles present in the first component. In yet other aspects, 19 the volume of the first component 802 and the volume of the second component 804 can be in any ratio depending on the desired application.

An exemplary multi-component fiber 900 shown in FIG. 9 has a circular radial cross- sectional shape and defines an axial void 906 that is centered in the fiber 900. The first component 902 and the second component 904 can be arranged circumferentially around the central axis of the fiber 900 in alternating radial segments. It is understood that such an exemplary fiber can have any desired number of segments. In the illustrated example, the first components 902 and 904 are alternately arranged around void 906. The first component, as shown herein, comprises the plurality of solid particles 908. While as illustrated herein, the second component is substantially free of particles. It is understood, however, that the second component can also comprise particles that can be the same or different. Also disclosed herein are aspects where the fiber can have any number of alternating segments of the first and second components and no axial voids or more than one axial void. FIG. 10 shows an exemplary fiber 1000 having the first component 1002 with the plurality of solid particles 1006 forming a sheath around the second component 1004. In this example, the first component 1002 has a smaller volume relative to the total volume of the fiber as it compares to the second component 1004. The illustrated unlimited example shows the second component being substantially free of the plurality of solid particles. However, aspects where the particles are present in the second component (whether they are similar to the particles present in the first component or different) are also included herein.

The multi-component fiber 1100 shown in FIG. 11 has a circular radial cross-sectional shape and includes a first component 1102, and a second component 1104. The first component 1102 can be at least partially encapsulated by the second component 1104, with a portion of the first component 1102 extending to the exterior surface of the fiber. The first component 1102 includes the plurality of solid particles 1106, while the second component 1104 as shown here is substantially free of any particles. Again, it is understood that the aspects that include having a plurality of solid particles in the second component are also disclosed. 20

The exemplary multi-component fiber 1200 shown in FIG. 12 has a circular radial cross-sectional shape and includes alternating chord segments of the first component 1202 and the second component 1204. The segments of fiber 1200 can have equal widths (as measured along a diameter of the fiber 1200), or the segments may have unequal widths to allow one of the components 1202, 1204 to occupy a greater surface area of the exterior surface of the fiber 1200. The first component 1202 can include the plurality of solid particles 1206 dispersed within it, while the second component 1204 can be substantially free of particles. Again, it is understood that the aspects where the second component comprises a further plurality of solid particles are also covered herein.

FIG. 13 shows exemplary fiber 1300, where the plurality of solid particles comprises a combination of particles having different shapes. For example, substantially circular particles 1306 are combined with more elongated particles 1308 and are disposed near or at the fiber’s surface 1302. In this exemplary aspect, the bulk of the fiber 1304 has a smaller concentration of the particles.

In yet other aspects an as discussed above, the fibers of the current disclosure can include more than two components and/or have any radial cross-sectional shape, including any of the shapes described herein.

In still further aspects, the first and/or the second polymer can comprise a polyolefin, a polyamide, a polyester, or a combination thereof. In certain aspects, the first polymer and/or second polymer can comprise a polyamide. In such aspects, the polyamide can be formed by condensation polymerization of a dicarboxylic acid and a diamine. Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid, 3,4’-diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-naphthalenedicarboxylic acid, phthalic acid, 4,4’- methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediactic acid, fumaric acid, and maleic acid. Representative 21 examples of such diamines include ethylene diamine, tetramethylene diamine, hexamethylene diamine, 1,9-nonanediamine, 2-methyl pentamethylene diamine, trimethyl hexamethylene diamine (TMD), m-xylylene diamine (MXD), and 1,5- pentanediamine. In some aspects, the polyamide can be formed by condensation polymerization of an amino acid (such as 11-aminoundecanoic acid) or ring-opening polymerization of a lactam (such as caprolactam or co-aminolauric acid).

In certain aspects, when the first polymer and/or second polymer comprises a polyamide, the polyamide can include, but not limited to, polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 56, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 611, polyamide 612, polyamide 6T, polyamide 61, polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide 12T, polyamide PACM12, and polyamide TMDT, polyamide 611, and polyamide 1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, and polyamide L6T/6I; and aramid polymers. In still further aspects, the polyamide can comprise a polyamide copolymer, for example but not limited to a polyamide 6/polyamide 66 copolymer, polyamide 6/polyamide 6T copolymer, polyamide 6I/polyamide6T copolymer, polyamide 66/polyamide 6T copolymer, or polyamide 12/polyamide MAMCI copolymer.

In yet other aspects, when the first polymer and/or the second polymer can comprise nylon 6, nylon 66, nylon 666, nylon 610, nylon 512, nylon 11, or nylon 12, or a combination thereof. In still further aspects, the first polymer and/or the second polymer comprises polyamide 6. Yet in other aspects, the first polymer and/or the second polymer comprises 6,6.

In still further aspects, the first polymer and/or the second polymer can comprise a polyester. A polyester, as defined herein, is a synthetic linear polymer whose repeating units contain ester functional groups, wherein these ester functional groups are integral members of the linear polymer chain. 22

Typical polyesters, as used in the present disclosure, can be formed by condensation of a dicarboxylic acid and a diol. Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid, 3,4’- diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-naphthalene dicarboxylic acid, phthalic acid, 4,4’-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10- dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3- cyclohexanedicarboxylic acid, 1,2-cyclohexanediacetic acid, fumaric acid, and maleic acid. Representative examples of such diols include monoethylene glycol, diethylene glycol, triethylene glycol, poly(ethylene ether)glycols, 1,3 -propanediol, 1,4-butanediol, poly(butylene ether)glycols, pentamethylene glycol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 1,14-tetradecanediol, 1,16-hexadecanediol, cis- 1,4-cyclohexanedimethanol, and trans-l,4-cyclohexanedimethanol.

In still further aspects, when the first polymer and/or the second polymer can comprise a polyester, the polyester can comprise polyethylene terephthalate ester, polypropylene terephthalate, polytrimethylene terephthalate ester, polybutylene terephthalate ester, or any combination thereof. It is understood that the mentioned herein polyesters comprise both homopolymers and copolymers. For example, when the polyethylene terephthalate ester is discussed, it can include homopolymers of the polyethylene terephthalate ester and copolymers of the polyethylene terephthalate ester. Similarly, when the polybutylene terephthalate ester is discussed, it can include homopolymers and copolymers of the polybutylene terephthalate ester and the like. In still further aspects, the fiber can comprise polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), or combinations thereof. In some other aspects, the exemplary polyesters can include polyethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(butylene terephthalate) (PBT), poly(ethylene isophthalate), poly(octamethylene terephthalate), poly(decamethylene terephthalate), poly(pentamethylene isophthalate), poly(butylene isophthalate), poly(hexamethylene isophthalate), poly(hexamethylene adipate), poly(pentamethylene adipate), poly(pentamethylene sebacate), 23 poly(hexamethylene sebacate), poly( 1,4-cyclohexylene terephthalate), poly( 1,4- cyclohexylene sebacate), poly(ethylene terephthalate-co-sebacate), and poly(ethylene- co-tetram ethyl ene terephthal ate) .

In still further aspects, when the first polymer and/or the second polymer comprises a polyolefin, the polyolefin can comprise polyethylene, polypropylene, or a combination thereof. While in still further aspects, the first polymer and/or the second polymer can comprise polyethylene. While in still further aspects, the first polymer and/or the second polymer can comprise polypropylene.

In some aspects, the first and/or the second polymers can have a low crystallinity. In certain aspects, that would also allow some additional transparency to the fibers. In certain aspects, the first and/or the second components can include a polyester polymer, a polycarbonate polymer, and other polymers that are at least partially optically transparent.

In some aspects, the first polymer and the second polymer comprise the same polymer, i.e., for example, and without limitations, polyester, or polyamide, or polyolefin. In other aspects, the first polymer comprises a polyamide, and the second polymer comprises a polyester. In some aspects, the first polymer comprises a polyamide, and the second polymer comprises a polyolefin. In some aspects, the first polymer comprises a polyester, and the second polymer comprises a polyamide. In some aspects, the first polymer comprises a polyester, and the second polymer comprises a polyolefin. In some aspects, the first polymer comprises a polyolefin, and the second polymer comprises a polyamide. In some aspects, the first polymer comprises a polyolefin, and the second polymer comprises a polyester. In some aspects, the first polymer and the second polymer each independently comprise a polyamide, either the same polyamide or two different polyamides. In some aspects, the first polymer and the second polymer each independently comprise a polyester, either the same polyester or two different polyesters. In some aspects, the first polymer and the second polymer each independently comprise a polyolefin, either the same polyolefin or two different polyolefins. In some aspects, various additives may be added to the second polymer to reduce its crystallinity to achieve partial or total transparency. 24

In some aspects, the first polymer comprises polyamide 6, and the second polymer comprises polyethylene terephthalate. In some aspects, the first polymer comprises polyamide 6, and the second polymer comprises polytrimethylene terephthalate. In some aspects, the first polymer comprises polyamide 6, and the second polymer comprises polyethylene. In some aspects, the first polymer comprises polyamide 6, and the second polymer comprises polypropylene. In some aspects, the first polymer comprises polyamide 6,6, and the second polymer comprises polyethylene terephthalate. In some aspects, the first polymer comprises polyamide 6,6, and the second polymer comprises polytrimethylene terephthalate. In some aspects, the first polymer comprises polyamide 6,6, and the second polymer comprises polyethylene. In some aspects, the first polymer comprises polyamide 6,6, and the second polymer comprises polypropylene.

In some aspects, the first polymer comprises polyethylene terephthalate, and the second polymer comprises polyamide 6. In some aspects, the first polymer comprises polyethylene terephthalate, and the second polymer comprises polyamide 6,6. In some aspects, the first polymer comprises polyethylene terephthalate, and the second polymer comprises polyethylene. In some aspects, the first polymer comprises polyethylene terephthalate, and the second polymer comprises polypropylene. In some aspects, the first polymer comprises polytrimethylene terephthalate, and the second polymer comprises polyamide 6. In some aspects, the first polymer comprises polytrimethylene terephthalate, and the second polymer comprises polyamide 6,6. In some aspects, the first polymer comprises polytrimethylene terephthalate, and the second polymer comprises polyethylene. In some aspects, the first polymer comprises polytrimethylene terephthalate, and the second polymer comprises polypropylene.

In some aspects, the first polymer comprises polyethylene, and the second polymer comprises polyamide 6. In some aspects, the first polymer comprises polyethylene, and the second polymer comprises polyamide 6,6. In some aspects, the first polymer comprises polyethylene, and the second polymer comprises polyethylene terephthalate. In some aspects, the first polymer comprises polyethylene, and the second polymer comprises polytrimethylene terephthalate. In some aspects, the first polymer comprises polypropylene, and the second polymer comprises polyamide 6. In some aspects, the 25 first polymer comprises polypropylene, and the second polymer comprises polyamide 6,6. In some aspects, the first polymer comprises polypropylene, and the second polymer comprises polyethylene terephthalate. In some aspects, the first polymer comprises polypropylene, and the second polymer comprises polytrimethylene terephthalate.

In some aspects, the first polymer and the second polymer each comprise polyamide 6. In some aspects, the first polymer and the second polymer each comprise polyamide 6,6. In some aspects, the first polymer comprises polyamide 6, and the second polymer comprises polyamide 6,6. In some aspects, the first polymer comprises polyamide 6,6, and the second polymer comprises polyamide 6.

In some aspects, the first polymer and the second polymer each comprise polyethylene terephthalate. In some aspects, the first polymer and the second polymer each comprise polytrimethylene terephthalate. In some aspects, the first polymer comprises polyethylene terephthalate, and the second polymer comprises polytrimethylene terephthalate. In some aspects, the first polymer comprises polytrimethylene terephthalate, and the second polymer comprises polyethylene terephthalate.

In some aspects, the first polymer and the second polymer each comprise polyethylene. In some aspects, the first polymer and the second polymer each comprise polypropylene. In some aspects, the first polymer comprises polyethylene and the second polymer comprises polypropylene. In some aspects, the first polymer comprises polypropylene, and the second polymer comprises polyethylene.

In one aspect, and as disclosed above, the further plurality of solid particles can be dispersed within the second polymer. In certain aspects, the further plurality of solid particles can have a concentration by volume in the second polymer that is less than a concentration by volume of the first plurality of solid particles in the first polymer. In some aspects, the further plurality of solid particles are evenly dispersed in the second polymer. In some aspects, the further plurality of solid particles have a concentration volume in the second polymer that is 10% less, 20% less, 30% less, 40% less, 50% less, 60% less, 70% less, 80% less, or 90% less than the concentration by volume of the 26 particles in the second polymer. In other aspects, the second component is substantially free of any plurality of solid particles dispersed in the second polymer.

In still further aspects, the fibers can also comprise additional additives such as fillers, flame retardants, reinforcing agents, thermal stabilizers, ultraviolet light stabilizers, hindered amine stabilizers, impact modifiers, flow enhancing additives, stabilizing agents, delustering agents, porosity additives, leveling agents, and the like, and any combination thereof. It is understood that the plurality of solid particles disclosed herein is different from the filler that can also be present in the fiber composition. In some aspects, the flame retardant additives can comprise, for example, decabromodiphenyl ether and triarylphosphates such as triphenyl phosphate and the like. In other aspects, the thermal stabilizers can comprise, for example, thermal conductivity improvers such as zinc oxide and titanium oxide. In other aspects, ultraviolet light stabilizers can comprise resorcinol monobenzoates, phenyl salicylate and 2-hydroxybenzophenones, and the like. In other aspects, hindered amine stabilizers can comprise benzotriazole, benzophenone, oxalanilide, and cerium oxide, and the like. In yet further aspects, fibers can further comprise ionomers; liquid crystal polymers; fluoropolymers; olefins including cyclic olefins; polyamides; ethylene vinyl acetate copolymers; stabilizing agents such as ortho-phosphoric acid, triphenylphosphate, and triethylphosphino acetate. In still further aspects, the delustering agents can comprise titanium oxide. While in other aspects, the fibers can also comprise carriers such as o- phenylphenol, p-phenylphenol, o-di chlorobenzene, trichlorobenzene, monochlorobenzene, biphenyl, methyl salicylate, butyl benzoate, benzyl benzoate, benzoic acid, benzalacetone, and methyl cinnamate. In yet still further aspects, the fiber can comprise leveling agents such as bishydroxymethyloxazoline, diaryl ethers, ditolyl ether, sodium di-naphthylmethane-B,B-disulfonate, ammonium dodecylbenzene sulfonate, sodium tetrapropylbenzene sulfonate, homopolymers or oligomers of N- vinylpyrrolidone and poly(tetrahydrofuran). While in still further aspects, the fibers can comprise porosity additives such as metal oxalate complexes, organic sulfonate salts, jade powder, and zeolite powder, and the like.

In still further aspects, the fibers disclosed herein can be staple fibers, bulk continuous filament, or any combination thereof. 27

Also disclosed herein is yarn comprising any of the disclosed herein fibers. In some aspects, the yarn is monofilament. In yet other aspects, the yarn is multifilament. For example, a plurality of any of the disclosed herein fibers can be combined into a yam.

In still further aspects, the yam is fully-drawn yam, spin drawn yarn, low- or not- twisted yarn, twisted yam, a flat yam, a textured yam, a high (HS) stretch textured yarn, a high-bulk textured yarn, or any combination thereof.

It is further understood that the yarn can comprise additional fibers that are substantially free of a plurality of solid particles. In such exemplary aspects, the additional fibers that are substantially free of the plurality of solid particles can have the same composition as any of the disclosed herein fibers or different composition (e.g., similar to the first and/or the second polymer), it can be mono-component fibers or multi-component fibers without any limitations. In such exemplary aspects, the one or more additional fibers comprise a polyamide, a polyester, a polyolefin, a natural fiber, or any combination thereof.

Also disclosed herein are flooring products comprising the disclosed herein yarns and fibers. It is understood that any portion of the flooring product can comprise these yarns and fibers. For example, and without limitations, the disclosed herein yams and fibers can be present in the face portion of the flooring product or any backing that comprises fibers. In still further aspects, the flooring product can be a carpet tile, a broadloom carpet, a mg, a turf, a mat, or any combination thereof.

METHODS

In still further aspects, disclosed herein are methods of forming any of the described above fibers. In such aspects, the methods comprise extruding a first composition comprising a first polymer and a plurality of solid particles to form a first component. In still further aspects, the method also can further comprise extruding a second composition comprising a second polymer to form a second component.

Example systems for spinning the multi-component fibers described herein include at least two extruders (e.g., an extruder corresponding to each component) and at least one spin pack that includes at least one spinneret that defines openings that form the radial cross-sectional shapes of the fibers spun therethrough. 28

In still further aspects, the fibers can be meltblown, spunbond or meltspun.

In still further aspects, also disclosed herein are methods of making described above yarns. In such aspects, the methods can comprise steps of blending, carding, drawing out, twisting, spinning, or any combination thereof, of the disclosed above fibers. Also disclosed herein are methods of making the flooring product. Depending on the portion of the flooring product been form, the method can comprise tufting the yarn to form a face portion of the flooring product or weave, knitting of the backings. The disclosed herein fibers and yarns can also be used to form non-woven fabrics that can be utilized in the flooring products. A number of aspects of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other aspects are within the scope of the following claims.

Claims

29 Claims

1. A fiber comprising: a first component comprising a first polymer; and a plurality of solid particles dispersed within the first polymer, wherein at least a portion of the plurality of solid particles is situated near, abutting, or exposed at a surface of the fiber, and wherein the plurality of solid particles comprise an active component.

2. The fiber of claim 1, wherein the plurality of solid particles form a concentration gradient from the surface of the fiber to a bulk of the fiber.

3. The fiber of claim 1, wherein the at least a portion of the plurality of solid particles situated near, abutting, or exposed at the surface of the fiber, is greater than a portion of the plurality of solid particles in a bulk of the fiber.

4. The fiber of any one of claims 1-3, wherein the active component comprises an antibacterial additive, an antifungal additive, an antiviral additive, or a bug resistant additive, insecticide additive, or a combination thereof.

5. The fiber of any one of claims 1-4, wherein the active component comprises a copper-containing compound, a zinc-containing compound, a silver-containing compound, or a combination thereof.

6. The fiber of any one of claims 1-5, wherein the active component comprises biguanides, essential oils, pyrethroids, terpenes, acyclic sesquiterpenoids, or any combination thereof.

7. The fiber of any one of claims 1-6, wherein the plurality of solid particles further comprise mica particles.

8. The fiber of claim 7, wherein the mica particles comprise wet-ground mica. 30

9. The fiber of claim 7 or 8, wherein the mica particles comprise muscovite, paragonite, biotite, lepidolite, phlogopite, zinnwaldite, clintonite, hydro muscovite, illite, phengite, or sericite.

10. The fiber of any one of claims 1-9, wherein the plurality of solid particles further comprise glass flakes, glass beads, or any combination thereof.

11. The fiber of any one of claims 1-10, wherein the plurality of solid particles further comprise a pigment.

12. The fiber of claim 11, wherein the pigment is incorporated in the glass flakes or glass beads.

13. The fiber of claim 10, wherein the plurality of solid particles provide a predetermined visual appearance to the fiber.

14. The fiber of claim 13, wherein the predetermined visual appearance comprises at least partial transparency, at least partial opacity, at least partial phosphorescence, at least partial fluorescence, at least partial light reflection, at least partial luster, or any combination thereof.

15. The fiber of claim 14, wherein the fiber has optical transparency from 40% to 100%.

16. The fiber of any one of claims 10-15, wherein the glass flakes comprise E-glass, C-glass, E-CR-glass, or combinations thereof.

17. The fiber of any one of claims 10-16, wherein the glass flakes or glass beads have been treated with a coating.

18. The fiber of claim 17, wherein the coating comprises a silane coating.

19. The fiber of claim 18, wherein the silane coating comprises a silane coupling reagent.

20. The fiber of claim 19, wherein the silane coupling reagent is selected from of 3- aminopropyltri ethoxy silane, vinyltrimethoxy silane, 3- glycidoxypropyltrimethoxy silane, or 3 -methacryloxypropyltrimethoxy silane, or a combination thereof. 31

21. The fiber of any one of claims 1-20, wherein the plurality of solid particles is from 0.01 wt% to 5 wt% by weight base on the total weight of the fiber.

22. The fiber of any one of claims 1-21, wherein the fiber further comprises a second component comprising a second polymer.

23. The fiber of claim 22, wherein the fiber is a bicomponent fiber having a side- by-side configuration, core-sheath configuration, a segmented configuration, or an islands-in-the-sea configuration.

24. The fiber of claim 23, wherein the fiber has the core-sheath configuration and wherein the second component is a core of the fiber, and the first component is a sheath of the fiber.

25. The fiber of claim 23, wherein the fiber has the segmented configuration and wherein the at least one of segments of the segmented configuration comprises the first component.

26. The fiber of any one of claims 22-25, wherein the second polymer is the same or different from the first polymer.

27. The fiber of any one of claims 22-26, wherein the second polymer comprises a further plurality of solid particles.

28. The fiber of claim 27, wherein the further plurality of solid particles is the same or different from the plurality of solid particles.

29. The fiber of any one of claims 22-28, wherein the second polymer is substantially free of any plurality of solid particles.

30. The fiber of any one of claims 22-29, wherein the first components defines at least 50 % of the total surface of the fiber.

31. The fiber of any one of claims 22-30, wherein a size of the plurality of solid particles and/or the further plurality of solid particles, if present, is substantially comparable to one of i) a cross-sectional size of the first component, ii) a cross- sectional size of the second component or iii) a cross-sectional size of the fiber. 32

32. The fiber of any one of claims 22-31 wherein the first polymer and/or the second polymer comprises a polyamide.

33. The fiber of claim 32, wherein the first polymer and/or the second polymer comprises polyamide 6.

34. The fiber of claim 33, wherein the first polymer and/or the second polymer comprises polyamide 6,6.

35. The fiber of any one of claims 22-34, wherein the first polymer and/or the second polymer comprises a polyester.

36. The fiber of claim 35, wherein the first polymer and/or the second polymer comprises polyethylene terephthalate.

37. The fiber of claim 35, wherein the first polymer and/or the second polymer comprises polytrimethylene terephthalate.

38. The fiber of any one of claims 22-33, wherein the first polymer and/or the second polymer comprises a polyolefin.

39. The fiber of claim 38, wherein the first polymer and/or the second polymer comprises polyethylene.

40. The fiber of claim 38, wherein the first polymer and/or the second polymer comprises polypropylene.

41. The fiber of any one of claims 22-40, wherein the first polymer and/or the second polymer is a low-crystallinity polymer.

42. The fiber of any one of claims 22-40, wherein the first polymer and/or the second polymer comprises polyester or polycarbonate having low crystallinity.

43. The fiber of any one of claims 1-42, wherein the plurality of solid particles have a concentration of at least 10% by volume within the first polymer.

44. The fiber of any one of claims 1-43, wherein the fiber is a staple fiber or a bulk continuous filament.

45. A yarn comprising the fiber of any one of claims 1-44. 33

46. The yarn of claim 45, wherein the yarn is a monofilament.

47. The yarn of claim 46, wherein the yam is a multifilament.

48. The yarn of claim 47, wherein the yarn is fully-drawn yarn, spin drawn yarn, low- or not-twisted yarn, twisted yarn, a flat yam, a textured yam, a high (HS) stretch textured yarn, a high-bulk textured yam, or any combination thereof.

49. The yarn of any one of claims 47-48, wherein the yam further comprises one or more additional fibers and wherein the one or more additional fibers are substantially free of a plurality of solid particles.

50. The yarn of claim 49 wherein the one or more additional fibers comprise a polyamide, a polyester, a polyolefin, a natural fiber, or any combination thereof.

51. A flooring product comprising the yarn of any of claims 45-50.

52. The flooring product of claim 51, wherein the flooring product is a carpet tile, a broadloom carpet, a mg, a turf, a mat, or any combination thereof.

53. The flooring product of claim 51 or 52, wherein the yam of any one of claims 42-47 is in a face portion of the flooring product.

54. A method of forming the fiber of any one of claims 1-44 comprising extruding a first composition comprising a first polymer and a plurality of solid particles to form a first component.

55. The method of claim 54 further comprising extruding a second composition comprising a second polymer to form a second component.

56. The method of claim 55, wherein the first composition and the second composition are coextruded to form a bicomponent fiber having a side-by-side configuration, core-sheath configuration, a segmented configuration, or an islands-in-the sea configuration.

57. The method of claim 56, the fiber has the core-sheath configuration and wherein the second component is a core of the fiber and the first component is a sheath of the fiber. 34 The method of claim 56, wherein the fiber has the segmented configuration and wherein the at least one of segments of the segmented configuration comprises the first component. A method of making the yarn of any one of claims 45-50 comprising steps of blending, carding, drawing out, twisting, spinning, or any combination thereof of the fiber of any one of claims 1-44. A method of making the flooring product of any one of claims 51-53 comprising tufting the yam of any one of claims 45-50 to form a face portion of the flooring product.