TWI638918B - Fibers and other constructs treated with diatomite particles - Google Patents

Abstract

The present invention relates to a structure composed of diatomaceous earth fibers, filaments, yarns, woven and non-woven fabrics, fiber-based films, mats, and separators; and other structures and finished products made of the foregoing. The subject matter of the present invention is particularly directed to apparel products and molded footwear outsole and other molded or fabric-like products in which a plurality of diatomaceous earth particles embedded in the surface of the construct impart desired functions such as moisture management, odor control, or traction or grip strength. Enhanced, water repellency and soil repellency and abrasion resistance.

Description

Fibers and other structures treated with diatomaceous earth particles [related application]

This application claims the benefit of priority to US Provisional Application No. 62/043, 911, filed on Aug.

background

In some aspects, the subject matter of the present invention is generally directed to moisture management of fibers, yarns, and fabric products. It relates in particular to moisture absorbing and transporting particles which are applied to fibers, yarns or fabrics to enhance moisture dissipation or to transfer moisture from the surface of the substrate material in which the particles are embedded. The subject matter of the present invention is particularly directed to fibers, yarns, and fabrics, such as fabrics, garments, tents, upholstery, and the like, incorporating diatomaceous earth (also known as "diatomite") particles. In other aspects, the subject matter of the present invention pertains to other articles embedded in diatomaceous earth on the surface, such as a footwear outsole incorporating diatomaceous earth particles, and a glove.

In the fiber and fabric industry, there is a need to provide improved, engineered products and components of the desired performance attributes. Moisture and heat management is one of these attributes. For example, in the sports and outdoor apparel industry, there are various known base and middle systems to help transport the skin of users. Skin moisture and evaporation of water. Some known solutions are based on the incorporation of carbonaceous particles derived from biological materials such as coconut and coffee waste on the surface of fibers and fabrics. Bioparticle-treated fibers have been used in, for example, jackets, substrates, self-waterproofing of hats and gloves, breathable laminates, and knits. The porous bio-particles used in the fabric fibers work with the user's body to adjust the temperature by accelerating moisture removal and improving drying time.

Despite the advantages of bio-particle-based technology, there is a constant need for better performing technologies for the next generation, and easier to use in manufacturing, lower cost, easy to derive from multiple geographic locations and more environmentally friendly technologies, and their solutions Applicable to other needs of the industry and end users.

One of the disadvantages of carbonaceous biomaterials is that they come from sources that are limited or geographically dispersed. For example, coconut derived materials must come from a dispersed coconut growth zone, which also results in reduced availability or increased transportation costs. Carbonaceous materials derived from biological materials are relatively soft and susceptible to abrasion under aggressive conditions. For example, it is not suitable for use under high wear conditions, such as in footwear outsole applications or work or sports glove applications. Prior art materials that are carbonaceous biomaterials may not be sufficiently inert to be easily handled or processed in the intended application. For the foregoing reasons and other reasons familiar to those skilled in the art based on the teachings herein and otherwise readily apparent, there is still a strong need for improved performance enhancing particles in the fiber, fabric and apparel and footwear industries, as well as in other industries covered herein. technology.

The subject matter of the present invention addresses the foregoing and other needs, and generally relates to structures composed of diatomaceous earth fibers, filaments, yarns, woven and non-woven fabrics, fiber-like films, mats, separators, and others made from the foregoing Constructs and finished products, as covered in more detail herein. The subject matter of the present invention relates in particular to apparel products and molded natural or synthetic rubber outsole and other molded or fabric types. A product in which a plurality of diatomaceous earth particles embedded in the surface of the structure impart desired functions such as moisture management, odor control, or traction or grip strength, water repellency and soil repellency, and abrasion resistance.

The diatomaceous earth particles are advantageously lightweight and not bulky. It can be blended with a base thermoplastic to form a durable, abrasion resistant and wash resistant structure.

When used in clothing articles, the adsorption and wicking capabilities of the surface-embedded diatomaceous earth particles allow the user to remain dry and more comfortable over a wide range of climatic conditions and environments. The subject matter of the present invention can be used in a wide range of apparel products including, but not limited to, the base and middle layers for running, snow sports, climbing and hiking applications. It can also be used in underwear, running shorts, cycling jerseys, golf shirts, etc. whenever water management is required.

Other advantages include the fact that the particles are natural products that are available from a variety of sources, including marine, lake, and terrestrial sources. It is affordable, stable and inert. It is easy to handle in manufacturing. And it can be chemically modified to provide special functions.

The foregoing is not intended to be an exhaustive list of specific examples and features of the subject matter. Those skilled in the art can understand other specific examples and features in light of the following embodiments in conjunction with the drawings. These and other specific examples are described in more detail in the following embodiments and figures. The following is a description of various words of the present invention under the subject matter of the present invention. The scope of the accompanying claims, which is hereby incorporated by reference in its entirety in its entirety, in its entirety, in its entirety, in the extent that it is incorporated herein by reference.

D‧‧‧ diatomaceous earth particles

1‧‧‧ filament

2‧‧ ‧ yarn

3‧‧ ‧ yarn

4‧‧‧ film

10‧‧‧Buildings

12‧‧‧The algae layer

14 ‧ ‧ layer

16 ‧ ‧ layer

18‧‧‧Upper body items

20‧‧‧ Lower body clothing items

27‧‧‧3D objects

28‧‧‧3D objects

90‧‧‧Buildings

100‧‧‧Buildings

200‧‧‧Buildings

210‧‧‧ system

212‧‧‧ Spinning head

214‧‧‧Reservoir

215‧‧‧jet

216‧‧‧埠/hole

218‧‧‧ Collector

220‧‧‧Sheet or mat

222‧‧‧ Down

300‧‧‧Universal shoes

310‧‧‧Sole unit

312‧‧ ‧ upper

314‧‧‧Front part

316‧‧‧Foot part

318‧‧‧ Collector

400‧‧‧ gloves

410‧‧‧Scratch area

The accompanying drawings show specific examples in accordance with the inventive subject matter, unless otherwise indicated.

Figure 1-2 shows that algae is a type of freshwater algae or algae.

Figures 3-22 show representative specific examples of the subject matter of the present invention, wherein the same or Generally similar features share a common reference number.

Figure 23 shows the appearance of water droplets on the surface of hydrophobic diatomaceous earth particles embedded or otherwise applied to the surface of the substrate.

Overview

Referring again to Figures 1 through 2, the algae are one type of freshwater algae or seaweed. The cell wall of the algae, known as "the algae shell", is made of milky white ceria (SiO ₂ ) and has a porous structure. A small amount of potassium, iron, calcium, magnesium, phosphate, sodium, titanium and other elements may also be included in the diatomaceous earth.

A large number of algae shells can be found in some marine and lake sediments and can be mined from them. Diatomaceous earth has long been used commercially as a filter, mineral filler, mechanical insecticide, insulating material, anti-caking agent, fine abrasive and other uses. Diatomaceous earth is generally considered to be non-toxic and inert.

Representative specific examples in accordance with the subject matter of the present invention are shown in Figures 3 through 22, wherein like or generally similar features share common reference numerals.

The subject matter of the present invention generally relates to a structure composed of diatomaceous earth fibers, filaments, yarns, woven and non-woven fabrics, fibrous films, mats and separators, and finished products made of the foregoing, especially garments and footwear. A product in which a plurality of diatomaceous earth particles embedded or otherwise applied to the surface of the structure impart desired functions such as moisture management (absorption and transport), thermal management (evaporative cooling), odour control, traction or grip strength, resistance Abrasive or water repellency (in the case where the prepared particles are hydrophobic). As used herein, a "diatomite" construct is a structure treated with diatomaceous earth particles that are embedded on the surface of the construct or coated or otherwise deposited on the surface of the construct.

The surface can be some or all of the outer and/or inner surface of the substrate material. The surface can be a generally outer cylindrical surface of the fiber. In some embodiments, the fibers can be hollow, in which case the surface can include the interior surface of the fibers. In other cases, the construct can be a fabric, in which case the surface can be one side or both sides of the fabric. In other cases, the construct may be a mat, membrane or mesh, in which case the surface may be any one or more exterior side surfaces of the construct or a surface comprised of voids or pores in the body of the fiber.

Diatomaceous earth fiber

In some aspects, the subject matter of the present invention is directed to fibers having a plurality of embedded diatomaceous earth particles. The particles are generally uniformly exposed on one or more of the fiber surfaces or at a desired spacing. The fibers are collected in bulk, or they can be collected on a spool and spun into yarns for use as a monofilament or collected into a mat, film or membrane to form a non-woven article.

In other aspects, the subject matter of the present invention relates to fabrics and other fibrous structures that use diatomaceous earth yarns, monofilaments, and/or multifilaments to form knitted or woven fabrics or other fibrous structures. The fabrics can be combined with other fabrics to form a composite fabric, such as a laminate of single layer units. The fabric can then be formed into a variety of end products, such as apparel products or footwear.

In another aspect, the subject matter of the present invention is directed to a method of making fibers incorporating diatomaceous earth particles. For example, particles are added to the feedstock of the polymer melt and dispersed into the melt. Subsequent use of various known fiber forming techniques (including spin melting, extrusion, blow molding, electrospinning, pressure spinning) and other techniques based on discharging polymer melt streams from micropores under pressure The molten composition is formed into fibers. Another possibility is to print the particles onto the substrate material using an inkjet type printing system in which, for example, the particles are dispersed in a binder. One of the advantages of this method is the ability to create a selected pattern on the substrate.

In still other applications, the diatomaceous earth particles can be sprayed onto the substrate, similar to how a non-slip surface (eg, a ship's deck) is coated with sand or sand particles. In still other applications, the diatomaceous earth particles can be applied to the substrate as a PU film, a thermoplastic film or a rubber (natural or synthetic) film in a thin layer. As discussed below, plasma treatment can be used to immobilize particles onto the fibers. Particles can be added to the plasma feed monomer solution and fixed to the fabric via the plasma. Or the particles may be coated with a pre-plasma, and the fabric or rubber material may then be placed into the plasma, wherein the plasma polymerizes the carrier monomer and immobilizes the diatomaceous earth particles into the polymer and onto the surface of the substrate. Figure 1 shows a representative diatomaceous earth powder. Figure 2 shows a representative diatomaceous earth particle D , i.e., a diatomaceous algae shell. The algae shells have a variety of configurations, each with a variety of pores or pores. The pores or pores typically have three different sizes ranging from a few microns to a submicron diameter. The number and size of the pores vary with the species of the algae. The different properties of the diatomaceous earth are based on the combination of the natural ceria composition, the overall structure of the algae shell particles and the network of pores in the structure. Some of the characteristics of diatomaceous earth are as follows: high porosity : 85% diatomaceous earth particles consist of interconnected pores. The diatomaceous earth particles are almost more ventilated than the diatoms.

High absorption : The diatomaceous earth particles can absorb a liquid having a weight of about 100% and still maintain some of the characteristics of the dried algae powder.

High surface to particle ratio : The algae particles are present in an irregular shape. The particle size range of the algae is typically in the range of less than 1 micrometer to several hundred micrometers but typically in the range of 2 micrometers to 200 micrometers. Interconnect channels increase surface area by several times compared to particles of the same diameter. This increases the reactive surface area without increasing the weight. The algae shell that crushes the algae produces a graded algae shell of nanometer size, wherein the graded algae shell maintains a porous network that provides the same function as the intact algae shell.

Absorption and deodorization : These are the natural characteristics of diatomaceous earth.

The diatomaceous earth generally has two grades: food grade (generally freshwater derived) and industrial grade (generally brine derived and used in swimming pools). The food grade has a low crystalline cerium oxide (<2%) content, while the industrial grade is reversed, which has a crystalline cerium oxide content of about 60+% by heating and treatment. Crystal cerium oxide may be detrimental to breathing and uptake. Food grade alfalfa has numerous uses in today's products and processes from toothpaste to cigar, plastic to paprika. For the pool, the diatomaceous earth is heated to a crystalline structure, so the pool of diatomaceous earth is industrial grade rather than food grade. In general, to help ensure human compatibility, the subject matter of the present invention encompasses the use of food grade diatomaceous earth approved by the FDA for comparison with industrial grade (filter grade) diatomaceous earth.

In some aspects, the present invention is directed to fibers having a surface comprising embedded diatomaceous earth particles. Fibers can be incorporated into fabric products to achieve improved moisture management, such as absorption, transport, or other functional effects, such as absorption of odorous molecules, enhanced traction, or other frictional effects. For example, the product can be a garment product that allows the user to maintain a dry, more comfortable environment over a wide range of climatic conditions and environments. The diatomaceous earth particles are lightweight and do not add significant weight or volume. When incorporated on the surface of a substrate by the methods disclosed herein, it is durable and abrasion resistant and wash resistant. The hardness scale of the diatomaceous earth particles is high and will not be easily worn during normal use of the product.

A novel diatomaceous earth fiber construct, which may be referred to herein as "diatomite fiber" (and similar expressions), may be formed by blending diatomaceous earth with a fiber raw material and subsequently forming a fiber. The resulting fibers will have embedded diatomaceous earth particles, including diatomaceous earth particles exposed on the surface of the fibers. Thus, it is known that fiber forming methods and systems can be used to form fibers having diatomaceous earth particles partially embedded in the fibrous base material and partially exposed on the surface of the material. This results in an increase in the surface area of the fiber, combined with the porous nature of the particles, promoting evaporative drying and cooling.

As used herein, the terms "fiber" and "filament" are used interchangeably. The term "long "Filem" generally refers to fibers having a high aspect ratio, such as fibers having relatively long or continuous lengths that can be wrapped around a desired article. In addition, synthetic fibers are typically produced in the form of long continuous filaments. In contrast, "staple fiber" generally refers to natural fibers, which tend to be relatively short, as this is how it typically grows. Long synthetic filaments can be cut into short staple fibers. In summary, the filaments are fibers, but the fibers can be of different lengths (cut or long or continuous). Filament generally also means a thin strand of material and encompasses yarns, threads, fibers, wires, cables, and similar fine strand structures that can be used to create knitted, woven, and non-woven fabrics. Filament 1, as seen in Figure 3, may be in the form of a monofilament or multifilament construct 2, such as a yarn, configured to act as a single strand material, as seen in Figure 4.

As used herein in connection with fiber or filament size, "diameter" means the diameter of a circular cross section, strictly speaking the word "diameter" and for the length of a non-circular cross section (eg, elliptical and polygonal). Wire, diameter means that the non-circular filaments have a cross-sectional area corresponding to a circular section giving the same cross-sectional area. In the case where the filament does not have a uniform diameter or cross-sectional area along the length, the average of the filament lengths can be used. (The average value can also be used for other non-uniform structures or material parameters related to this specification).

The polymeric fibers formed using the methods and devices of the present subject matter can have a range of lengths based on at least 100, 500, 1000, 5000 or a higher aspect ratio relative to the aforementioned fiber diameter. In one embodiment, the length of the polymeric fibers depends, at least in part, on the length of time during which the device is rotated or oscillated and/or the amount of polymer fed into the system. For example, the salty polymeric fibers can be formed to have a length of at least 0.5 microns, including lengths ranging from about 0.5 microns to 10 meters or more. In addition, the polymeric fibers can be cut to the desired length using any suitable instrument size, and the intermediate range of lengths is also part of the subject matter of the present invention.

The subject matter of the present invention is not limited to any particular size of fiber, filament or yarn. For For applications in the field of fabrics, footwear, and outdoor equipment, such materials will typically have filaments or yarns having a denier of 50-300 D or an approximate value. Some suitable yarn or other multifilament configurations for such applications may include, but are not limited to, 100 denier and 144 filaments; 75 denier yarns and 72 filaments; 50 denier and 48 filaments; and 50 denier and 36 filaments. Monofilaments with the indicated integral denier are also suitable for a variety of applications. The ratio of the number of denier/filaments is 0.25 to 2, or 0.5 to 1.5, 0.75 to about 1.25, or 1.0, or approximately any of the foregoing ranges, which are optimized for other yarn parameters (such as yarn) Surface area for strength, durability and processability to promote moisture and heat management. The closer the salt to Daniel/filament ratio is to 1, the better the wicking performance and moisture management will be, especially for yarns formed from microfibers.

In an exemplary embodiment, the suitable fiber size of the yarn is about 1 denier (microfiber) or an approximate value. Fibers of this size are expected to have good wicking capabilities. A denier polyester filament has a linear mass of 0.11 mg per meter of fiber, a density of about 1.38 and a diameter of about 10 microns. The diatomaceous earth particle size range can range from nanometers to 5 micrometers in diameter (for fibers). The diatomaceous earth particles have a non-uniform geometry, but will be treated or ground to pass through a sieve of a specified size range. For a 1 denier polyester fiber, the lower limit of the added diatomaceous earth particles will be 1% or about the weight of the fiber, and the upper limit will be 5% or about. Thus, in a 1 meter denier polyester fiber, 0.011 mg/m of algae (1% by weight of fiber) will be 0.0011 mg of algae per meter of fiber. The amount of algae on the surface will desirably be 100% and evenly distributed. The small surface area of the filaments, combined with the diatomaceous earth particles and the increased surface area attributable to the particles, results in a good interaction of the diatomaceous earth fibers with the water molecules, wetting the fibers and promoting the fibers and fabrics. Wicking (moisture movement) and drying.

As the yarn size changes, such as 50D/36 filament, 50D/48 filament, 70D/72 For filaments, etc., the diameter of the filaments changes and the linear weight of each filament changes. As the diameter of the filament increases, the weight will increase, resulting in an increase in the amount of algae per fiber weight. However, the increase in algae will still fall into 1-5% algae per fiber weight. Naturally, the filament of Daniel > 1 will have more algae than the algae specified above.

In addition, the above description assumes a circular cross-section fiber. As the fiber cross-section and geometry change, this can affect the surface area of the fibers that can be used for the algae to be placed. Hollow cores, circles, and core/sheath fibers are examples of similar diameters but different linear weights. However, the range of algae added will still be 1-5% by weight of the fiber.

Depending on the application, the diatomaceous earth particles may cover from greater than 0% to 100% of the surface of the structure made from the base material incorporated into the particles. In general, for moisture management particles, high coverage of the fiber surface through the particles is desirable so that the particles can transfer water molecules during active transport. However, an excessively high weight percentage of particles in the base material of the fibers can make the fibers brittle and unstable. The weight percentage of the salty algae soil particles to the thermoplastic base material is equal to or less than 5% or about the value does not substantially affect the stability of the underlying base material.

Treatment and diatomized soil fiber and fabric structure

Most synthetic and cellulosic fibers are produced by forcing a viscous liquid through the micropores of the device (referred to as spinnerets) to form continuous filaments of semi-solid polymer. In its initial state, the fiber-forming polymer is typically solid and must therefore first be converted to a fluid state for extrusion. If the polymer is a thermoplastic composition, this is usually achieved by melting, or if it is a non-thermoplastic cellulose article, it is achieved by dissolving it in a suitable solvent. If it cannot be dissolved or melted directly, it must be chemically treated to form a soluble or thermoplastic derivative. Developed for some specialized fibers made from polymers that do not melt, dissolve or form suitable derivatives Technology. For such materials, small fluid molecules are mixed and reacted during the extrusion process to form polymers that are otherwise difficult to handle.

Spinning heads for the production of most manufactured fibers are well known. The spinneret can have from one to several hundred holes. When the filaments appear from the pores in the spinneret, the liquid polymer condenses into a rubbery state and then solidifies. The extrusion and solidification process of this infinite filament is called spinning and cannot be confused with the operation of the fabric of the same name, in which the short pieces of the cut fibers are twisted into yarn. There are four methods for filament spinning of the produced fibers: wet spinning, dry spinning, melt spinning, and gel spinning.

In all of these processes, the spun polymer must first be converted to a fluid state. If the polymer is thermoplastic, it can only be melted, additionally dissolved in a solvent or chemically treated to form a soluble or thermoplastic derivative. The molten polymer is then pressurized through the spinneret and it is subsequently cooled to a rubbery state and subsequently solidified. If a polymer solution is used, the solvent is then removed after pressurization through the spinneret.

Wet spinning

Wet spinning is the oldest of the five methods. This method is used for polymers that need to be dissolved in a solvent for spinning. The spinneret is immersed in a chemical bath to cause fiber precipitation and subsequent solidification as it appears. This method derives its name from this "wet" bath. Acrylic fibers, rayon, aromatic polyamines, modacrylic fibers, and elastic rayon fibers (Spandex) are produced by this method.

A variant of the wet spinning is dry spray wet spinning in which the solution is forced into air and drawn, and then immersed in a liquid bath. This method is used to dissolve cellulose-soluble fiber (Lyocell).

Dry spinning

Dry spinning is also used for polymers that must be dissolved in a solvent. The difference is that solidification is achieved via evaporation of the solvent. This is usually achieved by the flow of air or an inert gas. Since no precipitation liquid is involved, the fibers do not need to be dried and the solvent is easier to recycle. Acetate fibers, triacetate fibers, acrylic fibers, modified polyacrylonitrile fibers, polybenzimidazole fibers, elastic rayon fibers, and vinyon are produced by this method.

Melt spinning

Melt spinning is used for polymers that can be melted. The polymer is solidified by cooling after extrusion from the spinneret. Nylon, olefin, polyester, saran and sulfar are produced by this method.

Extrusion spinning

The agglomerates or granules of the solid polymer are fed into the extruder. The agglomerates are compressed, heated and melted by an extrusion screw and subsequently fed into a spinning pump and a spinning head.

Direct spinning

The direct spinning process avoids the stage of solid polymer agglomeration. The polymer melt is produced from the raw material and subsequently pumped directly from the polymer processor to the spinner. Direct spinning is mainly used during the production of polyester fibers and filaments and is dedicated to high throughput (>100 tons/day).

Gel spinning

Gel spinning, also known as dry-wet spinning, is used to obtain fibers of high strength or other special characteristics. The polymer is in a "gel" state, only partially liquid, keeping the polymer chains slightly bonded together. These bonds create strong interchain forces in the fibers and increase their tensile strength. The polymer chains within the fibers also have a greater degree of orientation and increase strength. The fibers are first air dried and then further cooled in a liquid bath. Some high-strength polyethylene and aromatic polyamide fibers pass through this The method is produced.

Electrospinning

Electrospinning uses a charge to draw very fine (typically micron or nanoscale) fibers from a liquid-polymer solution or polymer melt. Electrospinning is a feature of electrospraying of fibers and dry spinning of conventional solutions. The method does not require the use of coacervation chemistry or high temperature to produce solid lines from the solution. This makes the process particularly suitable for producing fibers using large and complex molecules. Melt electrospinning is also implemented; this method ensures that no solvent can be brought into the final product.

Pressure spinning

Pressure spinning is another spinneret-based technology that can be used. Pressure spinning uses centrifugal force to force a flow of polymer material through the micropores, where the polymer stream becomes fine into fine fibers, which can be nanoscale. The pressure spinning is taught in PCT/US2014/045484, the entire disclosure of which is hereby incorporated by reference in its entirety in its entirety in the the the the the the the the

draft

After spinning, the fibers can be drawn to increase strength and orientation. This can be done while the polymer is still solidifying or after it has been completely cooled.

Spinning

The collected algae-derived fibers can be carded to form a yarn. Yarns can be used, for example, in apparel, footwear, and equipment end products, utilizing the unique properties that can be exhibited by diatomaceous earth fibers.

In addition to the foregoing polymer flow based on the spinneret, any other system that ejects a stream of polymeric material can be used. The fibers can be formed using known meltblowing techniques or other known techniques. For example, the name is "Multi-Pixel Liquid Streams, Especially Fiber-Forming Polymeric US 6392007 to Streams, And Methods And Apparatus For Forming Same, discloses a system and method in which at least two different streams are subdivided into a plurality of closely spaced parallel pixels that are individually separated to record inaccurate array orientations. Thus, individual pixels of one of the flow arrays will be surrounded by pixels of another flow array. The individual pixel arrays are then brought into contact with one another to form a multi-pixel stream consisting of two inaccurate pixel arrays of different liquid streams. The "pixelized" stream, i.e., the flow of the two different streams recorded in the cross section of the inaccurate pixel array, can then be further processed. For example, the pixelated liquid stream can be subjected to further mixing by being directed along a curved flow path.

Suitable base or base polymer materials include natural and synthetic polymers, polymer blends, and other fiber forming materials. These materials include thermoplastic polyurethanes, polyamides, polyesters, polypropylenes, polytetrafluoroethylene (PTFE), polypropylene (PP), polyurethanes (PU), polylactic acid (PLA). ), nylon, tantalum and β-indoleamine fibers and polyolefins. Polymers and other fiber forming materials can be made from biological materials (eg, biodegradable and bioresorbable materials, plant biopolymers, bio-based fermentation polymers), metals, metal alloys, ceramics, composites, and carbon super The fine fibers are composed of or include the above.

The fibers can include blends of a variety of materials as indicated above. The fibers may also include pores (eg, cavities or multiple lumens) or pores. Multi-chamber fibers can be realized by designing, for example, one or more outlet ports having concentric openings. In some embodiments, the openings can include separate openings (i.e., openings having one or more baffles such that two or more smaller openings are made). These features can be used to obtain specific physical characteristics. For example, fibers can be produced for use as thermal insulators in insulation applications such as those described below, or as elastic (resilient) or inelastic attenuators.

In some embodiments, the fabric constructs and films and fibrous webs of the present invention Elastane fibers, such as spandex, polyurethane, and polyacrylate polymers may be included to impart stretchability to the nonwoven fabric made in accordance with the teachings of the present invention.

In an illustrative embodiment, the subject matter of the present invention provides a diatomaceous earth fiber consisting essentially of polyethylene terephthalate as a fiber-forming polymer, characterized in that the diatomaceous earth/polymer of the fibers is From about 0.1% to about 5% by weight or about the value.

Depending on the application, the pores of the diatomaceous earth particles may or may not be blocked by thermoplastic or other base materials. The masterbatch typically produces a suspension of uniformly distributed particles and ensures that the particles are on the surface of the fibers and that the pores are open during extrusion. Blockage can be determined by microscopic methods, such as scanning electron microscopy. In some cases, blocking will not occur because, for example, the relative pore size of the particles is relative to: (1) the molecular weight or size of the polymer used in the base material; (2) the viscosity of the base material during blending; And/or (3) the surface tension of the base material during blending. If the base material is capable of blocking the pores, the particles may be pretreated by a substance that removably blocks the pores. Various methods are known, including those disclosed in US Pat. No. 7,247,374, incorporated herein by reference. In general, the removable material can be a thermoplastic or wax that reacts to environmental conditions other than the selectivity of the relevant base material. For example, the removable material can be dissolved in a particular solvent in which the base material is relatively insoluble. Similarly, a particular heating or rinsing method can be used to remove anything that can be used to fill or otherwise protect the pores or can inadvertently enter the pores. As another example, the removable material can degrade at a certain electromagnetic wavelength while the base material is stable.

In some embodiments, the exposed area of the particles on the surface of the base material of the fiber or other construct is between 3% and 50% or about the surface area of the base material. The diameter of the algae is typically about 1-3 microns and does not exceed about 5% of the fiber by linear weight. Micron size fiber The diameter can range from nanometers to a diameter of about 5 microns. In the case of nanofibers, the particles used may range in size from about 100 to about 500 nm.

Fabrics made from diatomaceous earth fibers in accordance with the teachings of the present invention may comprise from 0% to 100% diatomaceous earth fibers (in the case of weaving, for example, a substantially uniform distribution of weft yarns and/or warp yarn directions). In some applications, such as moisture management, a suitable performance attribute can be achieved by 10% to 100% of the yarn in the fabric. A particularly suitable performance attribute can be achieved if the fabric has a 30% or approximately diatomaceous earth yarn. 30% or more of the diatomized ground yarn in the woven fabric will provide a particularly suitable performance attribute.

One non-limiting example of a suitable polymeric material to which diatomaceous earth particles can be added is poly(trimethylene terephthalate) (PET), which can be used to form polyester materials. PET or "polyester" generally includes at least 80% polyethylene terephthalate units and from diols (except ethylene glycol, such as diethylene glycol, butylene glycol) or dicarboxylic acid (except terephthalic acid) For example, polyesters of up to 20% units of isophthalic acid, hexahydroterephthalic acid, dibenzoic acid.

In an exemplary embodiment, the present subject matter provides a method of producing a melt spun fiber comprising poly(ethylene terephthalate) as a fiber-forming polymer, which is condensed or melted via a fiber-forming polymer and then melted The body is melt spun into fibers to carry out. The method comprises the steps of mixing 0.1-5.0 wt% of diatomaceous earth into a polymer feedstock or polymer melt material followed by melt spinning. In general, the particles will be homogeneously dispersed in the molten material. Spinning speeds of from 500 m/min to 10,000 m/min during melt spinning should be suitable for many applications. During melt spinning, the fibers are extruded from one or more apertures of the spinneret of the melt spinning system.

PET itself may also contain customary additives such as matting agents (titanium dioxide), stabilizers, catalysts, dyes and the like. Polyethylene terephthalate ethyl ester can be seen in small moles Branching agent modification with 3-4 functional alcohols or acid groups, such as trimethylpropane, trimethyloctane, pentaerythritol, glycerol, symmetrical trimellitic acid, trimellitic acid or benzene acid.

However, the starting polyester may also contain known additives to modify the coloring ability, such as sodium-3,5-dicarboxybenzenesulfonate.

In the melt line, for example, other dynamic and/or static mixers may be used. For this purpose, the dynamic and/or static mixer can also be placed directly in front of the spinning assembly.

In one embodiment of the invention, the alternate dispersion, molten mixture, which may be produced by any of the described hybrid variants, is first unspun into fibers, but granulated. The granules can later be treated with a melt extruder on a conventional spinning machine and spun into fibers. In this process, the secondary processor, such as the customer of the granule manufacturer, has all the advantages of the polyester modified according to the invention without having to have its conventional spinning machine equipped with expensive dosing and mixing facilities and without having to purchase separate additive. Therefore, the entire process is as simple as a secondary PET granulation as a normal PET granulation.

In addition to the novel diatomaceous earth-forming fiber constructs, the subject matter of the present invention is generally also directed to forming woven, non-woven, and knitted fabric constructs based on the fusion of selected filaments (e.g., yarns or fibers), fabrics in fabric constructs. A lattice formed of yarn or fiber is produced in the asymmetric surface or layer. (The product and its corresponding components, or parts/portions of the product or component are generally referred to as "constructs"). As used herein, "lattice" means that the arrangement of points or elements is in a generally regular periodic pattern, particularly in the form of a cross, staggered, mutually circulated or interwoven, such as in a knitted or woven structure. Although not technically within the specification due to its irregularity in the shape of a cross or interlaced fiber, unless the context dictates otherwise, it is intended herein to include a fabric having a non-woven mat or felt form as a lattice structure. Fabric constructs can be based on what is known in the art The various techniques are formed by knitted or woven structures. It can be formed from a mat or felt structure based on various techniques known in the art.

Fig. 5 schematically shows a structure 10 comprising three layers: a layer of diatomaceous earth fabric 12, an outer layer 14 as the case may be, and an inner layer 16 as the case may be. The diatomized soil layer can be used to control moisture. In apparel applications, the outer layer in the outer sheath can be a shell. The inner layer can be a comfortable lining made of, for example, a mesh fabric for the skin of the user. If the layer 14 or layer 16 as the case may be omitted, the algae soil layer 12 may be used for sports, outdoor applications, and moisture management or other functions provided by the algae soil material, which may be desirable for such other purposes. The base layer.

FIG. 6 schematically illustrates an example of an upper body garment item 18 (eg, a sheath) and a lower body garment item 20 (eg, pants) that may be integrally or partially constructed with the construct 10.

More specifically, a fabric can be defined as any fabrication of filaments having a generally two-dimensional structure (i.e., having a length and width substantially greater than the thickness). In general, fabrics can be classified as non-woven fabrics or mechanically manipulated fabrics. Nonwoven fabrics are webs or mats of filaments that are bonded, fused, interlocked, or otherwise joined. As an example, a non-woven fabric can be formed by randomly depositing a plurality of polymer filaments on a surface, such as a moving conveyor belt. Mechanically manipulated fabrics are typically formed by weaving or reciprocating (e.g., knitting) a yarn or a plurality of yarns, typically via a mechanical process involving a loom or knitting machine. However, the woven fabric includes yarns (i.e., warp and weft) that intersect each other at right angles, and the knit fabric includes one or more yarns that form a plurality of interengaging rings in the latitude and loop configurations.

As used herein, "film" means a thin, monolithic layer of material. The membrane may or may not have porosity, but if it is porous, it has a substantially solid surface area, i.e., the openings do not occupy a substantial portion of the surface area. For example, at least one solid surface area of the membrane can range from about 50% to about 100%, and includes 50%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99%, 99.9%, and 99.99% solid surface area.

As used herein, "membrane" means separating two fluids (eg, water or air outside the garment and air or vapor inside the garment (on the side of the user)) and acting as a membrane for the selective barrier unless the membrane is A hydrophilic membrane that otherwise allows some particles to pass preferentially with respect to other particles, such as allowing gas phase water but non-liquid phase water to pass through (eg, microporous and hydrophobic membranes).

The fibers, yarns, threads, and fabrics disclosed herein can be used in a variety of apparel articles (e.g., outerwear, shirts, and footwear) and a variety of other articles. For example, fabric constructs can be used in seamless and seamed products and product components, such as garments; footwear; gloves; headwear; tents; backpacks; containers or carriers of the nature of luggage and other object carriers; Supplies; tablecloths; linens; car seat covers; tarpaulins; towels; medical fabrics; geotextiles; and agricultural fabrics, wherein the structures comprise the structures claimed herein (diatomaceous earth fibers, filaments, yarns, At least a portion of any of a fabric, mat, film or membrane. Various configurations of fabric constructs can also be used for industrial purposes, such as in automotive and aerospace applications, filter materials, medical fabrics, geotextiles, agricultural fabrics, and industrial apparel. Diatomaceous earthen fibers and fabrics can also be used in gloves to provide a grip side with better grip. Thus, fabric constructs can be used in a variety of articles for personal and industrial purposes.

In certain embodiments, the present subject matter is directed to a fabric construct and associated construction method in which fusible filaments, such as thermoplastic yarns or fibers 3 (FIG. 7) in lattice 90, are melted to form fabric construct 100 or 200. It has a partially fused film (Fig. 8) or a fully fused film 4 (Figs. 9-10) on one side or layer while the other side or layer remains in a discrete knit or woven structure. The diatomized earth filaments or yarns in the fabric may be on one or both sides or layers of the structures 90, 100 and 200. Various fabric constructs having fusible filaments are disclosed in U.S. Patent Application Serial No. 61/943,349, the entire disclosure of which is incorporated herein by reference. The fused membrane can provide a membrane side or layer having desirable properties such as water repellency or water resistance and gas permeability. The fusion membrane provides a variety of functional or performance attributes. For example, it may act as a complete or partial barrier to air and water depending on the materials used and/or degree of fusion. It can act as a stretchable layer that fits snugly. It can act as a durable or protective layer against wear or impact. Any combination of these functional characteristics can be engineered into a fabric construct in accordance with the subject matter of the present invention.

Fig. 7 shows an example of a woven knit structure in which the structuring body 90 is formed by one of the plating yarns composed of the diatomaceous earth yarn 2 and the fusible fiber 3. (The fusible yarn has a lower softening or melting temperature relative to the non-fusible material). The addition of the yarns 2 and 3 to the opposite side of the plating structure. Upon softening or melting the fusible fibers, the fusible fibers form a partially or fully molten structure on one side of the building and the discrete knit structure will remain on the other side. Fig. 8 shows the structure 100 from the side of the non-fusible yarn 2, which is produced by partial melting from the structure 90 of Fig. 7. Figure 9 shows the structure 100 from the side of the non-fusible yarn 2, which is produced by complete melting of the structure 90 from Figure 7. Figure 9 shows the structure 200 from the side of the fusible yarn 3 (now appearing as film 4), which is produced by the complete melting of the structure 90 from Figure 7.

While a wide range of thermoplastic polymer materials are useful for fusible filaments, examples of suitable thermoplastic polymer materials include thermoplastic polyurethanes, polyamides, polyesters, polypropylenes, and polyolefins. While the fusible filaments can be formed from any of the thermoplastic polymer materials mentioned above, the use of thermoplastic polyurethanes imparts various advantages. For example, thermoplastic Various formulations of the urethane are elastomers and stretch over one hundred percent while exhibiting relatively high stability or tensile strength. Thermoplastic polyurethanes are susceptible to thermal bonding with other elements as compared to some other thermoplastic polymeric materials, as discussed in more detail below. In addition, the thermoplastic polyurethane can form a foam material and can be recycled to form a variety of products. In many configurations of fusible yarn 2, each of the bundled component filaments 1 is formed entirely or substantially of one or more thermoplastic polymer materials. That is, at least 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% or 100% by weight of the filament 1 is a thermoplastic polymer material. The advantage of forming the filament 1 substantially from the thermoplastic polymer material is uniformity, which enables thermal bonding, efficient manufacturing, elastic stretching and relatively high stability or tensile strength. While a single thermoplastic polymer material can be used, the individual filaments 1 can be formed from a variety of thermoplastic polymer materials. As an example, the individual filaments 1 may have a sheath/core configuration in which the outer filament 1 outer sheath is formed from a first thermoplastic polymer material and the inner core of the individual filaments 1 is formed from a second thermoplastic polymer material. As a similar example, the individual filaments 1 can have a two-component configuration in which one half of the individual filaments 1 are formed from a first thermoplastic polymer material and the opposite half of the individual filaments 1 are formed from a second thermoplastic polymer material. Although the individual filaments 1 can be formed from a common thermoplastic polymer material, the different filaments 1 can also be formed from different materials. As an example, some of the filaments 1 may be formed from a first type of thermoplastic polymer material, while other filaments 1 may be formed from a second type of thermoplastic polymer material.

In addition to the thermal means for converting the fusible filaments into a film, other devices or energy sources can be used alone or in combination with thermal energy to convert into a film. For example, a mechanical press can be used to promote the formation of a film under sufficient conditions by using filaments having wax or clay-like properties and coalescing and fusing under sufficient pressure. The filaments may also be in a polymerization agent (such as a chemical) or an energy source (for example, UV or Electromagnetic radiation or ultrasonic energy in the IR spectrum exists in a polymerizable material that is bonded together. Filaments may also have the property that they soften and become fusible in the presence of a particular solvent or gas.

The polymeric material of filament 1 can be selected to have various tensile properties and the material can be considered an elastomer. Depending on the particular characteristics desired for the yarn, the filament 1 can be stretched between ten percent and more than eight hundred percent before the tensile failure. Relatedly, the thermoplastic polymer material used in filament 1 can be selected to have various recovery characteristics. That is, the yarn or filament 1 may be formed to return to the original shape after being stretched. Many yarn-containing products, such as fabrics and garment articles formed from fabrics, may benefit from allowing the yarn to return or otherwise return to its original shape at one hundred percent or more after being stretched. . While many thermoplastic polymer materials exhibit tensile and recovery characteristics, thermoplastic polyurethane exhibits suitable stretch and recovery characteristics for a variety of fabrics and apparel articles.

The yarn weight can vary significantly, for example, depending on the thickness of the individual filaments 1, the number of filaments 1, and the particular material selected for filament 1. In general, the weight is measured by the unit "Tex" or "Daniel", which is the weight of a certain metric yarn in grams, as understood by those skilled in the art.

A variety of conventional methods are available for making yarns composed of one or more thermoplastic and/or diatomaceous earth fibers or filaments 1. In general, the method of making the yarn 1 comprises (a) extruding or otherwise forming a plurality of filaments 1 from the diatomaceous earth and/or thermoplastic polymer material and (b) collecting or binding the filaments 1. After the binding, the filament 1 can be twisted. Depending on the particular feature desired, the yarn may also undergo an air texturing operation or other post-processing operation. A fusing process as discussed below can also be performed to form a thermal bond between adjacent filaments 1.

The subject matter of the invention also encompasses fabric constructs in which the constitutive filaments or yarns are customized Occurs after the formation of the filament yarn or fabric. For example, the articles may be formed from all or a portion of the thermoplastic material, and the diatomaceous earth may be embedded in the surface of the article while being in a molten or softened state. This can occur, for example, by mechanically pressing or kneading the particles into a thermoplastic substrate or air jet to force the particles into the surface.

The particles may also be attached to the softened, molten or solid substrate surface of the thermoplastic and non-thermoplastic material via chemical bonding. For example, the diatomaceous earth particles can be dispersed in an epoxy resin solution and applied to a substrate.

As indicated, fabric constructs in accordance with the subject matter of the present invention can be incorporated into a variety of products, including various apparel items (eg, shirt pants, footwear). Taking a set of outer garments (Fig. 6) consisting, for example, of a sheath or casing 18 and pants 20 as an example, the diatomaceous earth fabric construct can form a majority of each garment, including the torso region of the sheath or casing. And the two arm areas and the waist and leg areas of the pants. One or more fabric constructs can be selectively placed in areas that may require any of the foregoing or performance attributes. For example, in the base layer, the algae soiled structure can be in the area under the arm, the chest and/or back area, or any other area that is prone to sweating.

The subject matter of the present invention also encompasses the use of diatomaceous earth particles that have been modified to provide selective functionality. For example, US Pat. No. 8,216,674 to Superhydrophobic Diatomaceous Earth discloses superhydrophobic diatomaceous earth. The diatomaceous earth is prepared by coating the diatomaceous earth particles having a hydrophobic coating on the surface of the particles such that the coating conforms to the surface topography of the diatomaceous earth particles. The hydrophobic coating can be a self-assembled monolayer of a perfluorinated decane coupling agent. The superhydrophobic powder can be applied as a suspension in the polymer feedstock as discussed above, or applied to a substrate in a binder solution to create a superhydrophobic surface on the substrate.

Hydrophobic diatomaceous earth can be used, for example, in yarns as a water repellent treatment for structures. its The durability of the structure can also be enhanced by its hardness. For example, hydrophobic diatomaceous earth can be used in yarns to enhance water repellency. It can be used in fabrics to provide water repellency and abrasion resistance. In the outsole of the shoe (discussed below), the hydrophobic diatomaceous earth helps prevent water from entering the diatomaceous earth particles.

The application PCT/US2014/045484, which is hereby incorporated by reference in its entirety, is hereby incorporated by reference in its entirety in the in the in in in in in in in in in in in in in in in in in in in in in in in in in in in . In some aspects, the subject matter of the present invention relates to the production of articles and article assemblies using novel methods for forming a jet of material solidified into diatomaceous earth fibers, which may be ultrafine diatomaceous earth fibers. And a two-dimensional or three-dimensional network is formed as it is collected. The object of the present invention is also directed to systems and methods for collecting, for example, diatomaceous earth fibers of any size suitable for use in forming the objects of the present invention as well as for collecting agglomerates such as generally parallel strands suitable for forming yarns.

An exemplary spinneret-based system is schematically illustrated with reference to Figures 11-13 and 16-19. In a representative example, the system is a pressure spinning system for producing diatomaceous earth fibers and collecting them in a desired form, such as oriented strands or viscous webs, such as films or mats. However, the principles disclosed herein will generally be applicable to other systems based on the injection of flowable polymeric materials, such as those described herein above.

System 210 includes a spinneret 212 fluidly coupled to a source of fluid or flowable material, the fluid or flowable material comprising dispersed diatomaceous earth particles, which may be formed into diatomaceous earth fibers ("fiber forming materials"). The material source can be a reservoir 214 that continuously feeds the spinneret. The spinneret itself may comprise a reservoir of polymeric material having dispersed diatomaceous earth particles as the spinneret rotates. The flowable material can be a molten material or a solution of material. The spinneret is mechanically coupled to a motor (not shown) that rotates the spinneret in a circular motion. In some embodiments, the rotating element is between about 500 RPM and about 100,000 Rotate within the RPM range. In some embodiments, the rotation of the spray material during it is at least 5,000 RPM. In other embodiments, it is at least 10,000 RPM. In other embodiments, it is at least 25,000 RPM. In other embodiments, it is at least 50,000 RPM. During rotation, a selected material, such as a polymer melt or polymer solution, is sprayed from material jet 215 from one or more outlet ports 216 on the spinneret into the surrounding atmosphere. The outward radial centrifugal force extends the polymer jet as the polymer jet projects away from the exit weir, and the jet travels along the curling trajectory due to rotation-dependent inertia. The stretching of the extruded polymer jet 215 is important in reducing the jet diameter within the distance from the nozzle to the collector. The blasting material is expected to solidify into diatomaceous earth fibers as it reaches the collector. The system includes a collector 218 for collecting fibers in a desired manner. For example, the fibers can be sprayed from the spinneret onto a surface disposed beneath the spinneret or from the wall of the spinneret. The collection surface can be static or mobile. To form a sheet or mat 220 of fibrous material, the surface can be a flat surface. The flat surface can be static or movable.

The movable flat surface can be part of a continuous belt system that feeds the fibrous material into a drum or other processing system. Another processing system can be an in-line lamination or material deposition system for laminating or depositing other materials onto sheet materials produced using other systems of pressure spinning systems or sheeting materials for producing microfibers. In other embodiments, a flat surface can support another layer of material on which the fibers are deposited. For example, the layer of material on which the diatomaceous earth fibers are deposited may be the inner or outer layer of the composite component layer of the final product, such as a garment article.

In some embodiments, the collection surface is a 3D object (such as a mold) or a 3D component of the final product. Figures 11 through 12 schematically illustrate examples of 3D articles 27, 28 of a final product shoe or glove. Fig. 5 schematically shows a 3D article in the form of a down 222 having a fiber extension 1 that can be replicated, as discussed in more detail below. To guide the fibers to the desired collection The surface ("collector"), the fiber guiding system, forms part of the pressure spinning system. For example, the orientation system can be configured to provide air from above the desired collector and/or provide a vacuum underneath to direct the fibers to the collector.

When the diatomaceous earth fibers are placed with each other, contact points are made at the intersections, and the separator components are bonded together. If a mesh bond of the contact points is desired, it can be accomplished via a web bond that requires contact points, which can be accomplished by applying heat (thermal bonding), heat and pressure, and/or chemical bonding. The pressure spinning system can include a heating element, a pressure applicator, and a chemical bonding unit for effecting the bonding.

In accordance with the inventive subject matter, spinning of a fiber-forming polymer can be used to provide a plurality of layers of diatomaceous earth or conventional fibers using a combination of spinneret hole size, pore geometry, and configuration.

Other diatomaceous earth fibers can be made to have different cross sections in the form of round, unfolded circles (i.e., substantially circular fibers, hollow at the center, i.e., compressed into an ellipse) or in the form of a flat strip. Additionally, different spinnerets can be included in the pressure spinning system resulting in different fiber diameters or blends. For example, multiple spinnerets in a system can produce a fiber blend during spinning. The spinneret can also be configured with an exit port that produces a core-sheath structure. Alternatively, a single spinneret has a plurality of outlet ports, each coupled to a different flowable reservoir, and the fiber forming material can produce a blend of diatomaceous earth fibers and conventional fibers.

Similarly, the properties of the diatomaceous earth fibers can be controlled by providing different outlet ports having different selected diameters on the rotating device. The subject matter of the present invention encompasses a range of exit pupil diameters between about 1 micrometer and about 1000 micrometers. Larger diameters are also covered if relatively high diameter fibers are required. The passage or aisle leading to the exit raft will typically have a straight run. It can be up to 1-3 mm.

In a given system, the diameter and/or shape or size of the exit weir may be uniform or may vary. In some embodiments, the exit weir is formed as a predetermined length of nozzle having a reduced taper toward the weir. The exit enthalpy and associated aisles or channels can be formed using known micro-grinding techniques or techniques to be discovered. Known techniques include mechanical grinding, chemical etching, and laser drilling and ablation. In addition to microfibers, pressure spinning systems in accordance with the subject matter of the present invention can be used to produce fibers of standard fabric size (e.g., 50-150 denier).

The microfibers or other fibers may include functional additives such as, but not limited to, antimicrobial agents, metals, flame retardants, and ceramics. These materials can be introduced into the spinneret along with the fiber forming material. It can be covalently bonded to the material by, for example, hydrogen bonding, ionic bonding, or van der Waals force. A catalyst can be included in the material mixture to promote any such bonding.

In any case, for the final product mentioned above, fiber mats (ranging in different fiber sizes, materials or blends) can be layered together to produce the entire garment composite or in the case of 3D objects throughout the final product For example, shoe composites and gloves.

The fiber forming material can be selected by the melting temperature to provide the final different structural rigid end product upon heat curing after pressure spinning or other spraying techniques. This can be especially important for 3D structures (such as gloves and uppers) that require relatively more durable than other end products, such as outerwear.

The subject matter of the present invention contemplates the use of pressure spinning to produce a layer of diatomaceous earth fibers or membranes for use in 2L, 2.5L and 3L waterproof/breathable products. For example, the algae soil layer can be adjacent to the membrane layer to aid in transporting moisture through the membrane. Used as a lining fabric, the algae can absorb moisture and transfer it directly to the membrane for subsequent transfer through the membrane. Algae adjacent to the membrane and adjacent to the surface layer can also provide a dry feel and keep liquid moisture away from the wearer.

After the fabric construct or membrane is formed, it may or may not be coated with a protective film to protect the pores from contamination. Depending on the end use of the membrane, the fibers may optionally be extruded through an oleophobic component to protect the membrane from dirt and oil contamination, or an oleophobic coating may be applied after the membrane is spun. Coating with an oleophobic coating will not cover the pores in the membrane or adversely affect gas permeability or air permeability, but will modify the surface of the nanofiber so as not to attract dirt and oil and thus prevent contamination. Those skilled in the art will see two examples of the wet curing process and the vapor/plasma deposition process applied as a means of applying an oleophobic coating or other coating to the algae without clogging the pores. Particles exhibit unique properties when they are in the nanometer range. It is a unique characteristic that includes superhydrophobicity. It is treated with a nano-sized hydrophobic algae. These hydrophobic nano-sized particles, when applied to the surface of the fabric, produce superhydrophobicity similar to the "Lotus Leaf" effect, providing water repellency and self-cleaning properties, as described in more detail below.

The diatomaceous earth film or membrane can be directly spun onto the fabric of the selected side of the final material, or the membrane can be spun onto the contact paper and subsequently laminated to the fabric of the selected side of the final material. Films or membranes deposited directly onto the fabric or material or laminated to the material can also be used in soft shell construction. The diameter of the diatomized soil fibers affects the pore size of the membrane or membrane. The cross-sectional morphology of the fibers and the fiber thickness affect the surface area of the fibers. Increasing the fiber surface area reduces the pore size. Reducing the fiber diameter is a way to increase the surface area to volume ratio. Therefore, the fiber diameter is a means of controlling thickness, durability, and water vapor transfer. The thickness affects the weight of the diaphragm. In general, these factors affect the permeability and durability of the diatomaceous earth-reinforced fibrous membrane or membrane. The diameter of the diatomized soil fibers according to the subject matter of the present invention can be in any fiber production size, including in the nanometer range. Some of the waterproof gas permeable membranes described herein are suitable for use in the range of from about 100 nm to about 1000 nm. The pore size affects air permeability. Therefore, for most applications, the air permeability of the diaphragm can be used in the aforementioned sizes. Nanofiber control within the range. Fiber forming materials for soft shell and waterproof breathable applications and other possible applications include PFTE dispersions, polyurethanes, nylon, polyester, bio-based materials (eg, such cellulosic materials, silk proteins) and Other fiber forming materials to be discovered (including other polymers derived from natural and synthetic sources).

In some embodiments, the flowable fiber forming material can be a mixture of two or more polymers and/or two or more copolymers. In other embodiments, the fiber forming material polymer can be a mixture of one or more polymers and/or copolymers. In other embodiments, the fiber forming material can be a mixture of one or more synthetic polymers and one or more naturally occurring polymers.

In some embodiments according to the inventive subject matter, the fiber forming material is fed into the reservoir as a polymer solution, i.e., a polymer dissolved in a suitable solution. In this particular example, the method can further comprise dissolving the polymer in a solvent prior to feeding the polymer into the reservoir. In other embodiments, the polymer is fed into the reservoir as a polymer melt. In this particular example, the reservoir is heated at a temperature suitable for the molten polymer, such as at a temperature of from about 100 °C to about 300 °C.

In some embodiments according to the inventive subject matter, a plurality of polymeric diatomaceous earth fibers of a micron, submicron or nanometer size are formed. A plurality of micron, submicron or nanometer sized polymeric fibers can have the same diameter or different diameters.

In some embodiments, in addition to conventional fiber sizes, the methods of the present subject matter result in the manufacture of micron, sub-micron or nano-sized diatomaceous earth fibers. For example, it is possible to make polymeric fibers of a diameter (or a similar cross-sectional dimension of a non-circular shape) of the following: about 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65 , 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, 1000 nm or 2, 5, 10, 20, 30, 40 or about 50 Micron. The intermediate size and extent of the diameter are also part of the subject matter of the present invention. Yanxin pressure spinning is one of the possible techniques for producing the aforementioned ultrafine diatomized soil fibers.

Yarn formation

After the fibers are produced, the fibers are made into yarn. For synthetic fibers, there are two types of yarn: filament yarn and spun yarn. Filament yarns are composed of a plurality of ultra-long fibers that are coalesced together and are typically oriented parallel to each other with a longitudinal axis. Filament is a single continuous fiber that has been extruded. The filaments may be gathered or coalesced together with individual fibers in a generally parallel orientation. The aggregate fiber bundle is then twisted to produce a thicker and stronger yarn. The fabric uses multifilament and monofilament.

Synthetic spun yarns are produced using staple fibers. The staple fibers are staple fibers having a length of from about 0.75 to about 18 inches. Silk is not included, and natural fibers are cut fibers. To produce a synthetic staple fiber, the fiber is extruded, drawn and tensioned or crimped, and then cut into staple fiber lengths. These staple fibers are then tightened for subsequent processing into a woven, knitted or non-woven fabric. The staple fibers are then combined and spun to produce a yarn consisting of thousands of short filaments. These spun yarns are produced in much the same way as cotton or wool yarns are produced.

Carding to unwind, clean and orient fibers into a continuous web for spinning Mechanical process. This process breaks up unstructured fiber clots and aligns fibers of similar length. Natural fibers, such as wool and cotton, are typically clots of entangled fibers of varying fiber lengths. The clots are carded and combed into parallel lengths of similar length to cut the fibers. These cut fibers are then spun into yarns for weaving and knitting fabrics.

In the case of a cotton tuft, the basic carding process includes: opening a bundle into individual fibers, removing impurities, selecting fibers based on length (removing the shortest), removing fluff, orienting the fibers in a parallel manner, and stretching the fibers, Converting the lap into a sliver results in a conventional quality flawless fiber. The sliver is a long bundle of fibers produced for spinning. All of the foregoing statements regarding yarn formation apply to yarns formed from diatomized earth filaments.

Cutting fiber

As indicated above, the fibers can be cut and carded to cut fibers. It is possible to change the size of the spinneret and increase or decrease the diameter of the pores to stretch the larger diameter fibers. For example, a range of, for example, 1 denier to 300 denier or an approximate value of Daniel is covered by the pressure spinning process. A given spinneret can have one or more holes that are all the same size. Or it may have a plurality of holes of different diameters or configurations for a plurality of fiber deniers or configurations.

Fiber mats composed of fibers in the range 1D-300D can function similar to fiber mats of natural fiber (e.g., cotton and wool) bundles. It is believed that, with the novel systems disclosed and encompassed herein, loose packing mats or batt of long continuous pressure spun fibers can be processed into staple fibers using the same process for natural fibers. Wool, cotton, jute, etc. can use different mechanisms for the comber and the carding machine. Thus, there are a number of options available to separate the spun fiber mat into staple fibers of the desired length.

The use of cut fibers from pressure spinning advantageously uses very little energy. Long continuous filament The coalescence is in a generally parallel orientation and it can be easily cut and carded to produce a uniform cut of the fibers. Conventional processes are limited by fiber size. Additionally, as disclosed herein, pressure spinning provides the ability to produce fibers from a variety of raw materials. In contrast, conventional processes have limited capabilities to efficiently produce a variety of natural, synthetic, and bio-fibers. For example, the polyester can be extruded in the form of long continuous filaments, such as fishing lines. These filaments can be used or cut into staple fibers. For pressure spinning, the fibers are relatively long compared to electrospinning, and the mat can be subsequently cut and carded, such as stapled fibers. The fiber mat represents a bundle of unoriented cut fibers. However, it is expected that the fiber strength increases as the pore size of the spinneret increases to 50 and fiber deniers above 50. Because of this, the length of the extruded fibers can be increased. Parameters such as rotational speed, pore size, and solution melt are expected to be suitable for the desired result without undue experimentation. In any case, i.e., nanofiber compression spinning is a large denier fiber, a similar method is followed by carding and cutting into staple fibers.

Pressure-spun continuous filament fiber

From nanometer scale to larger diameter, the subject matter of the present invention relates to the production of longer and more continuous algae-derived filaments from pressure spun fibers or other jetting techniques. Pressure spinning is used as a representative example, from 1 denier to 300 denier or approximately the relatively large fiber diameter, as well as other denier or diameters disclosed herein. The tensile strength of the filament increases as the fiber diameter increases.

In conventional extrusion processes, the pressure spinning process disclosed herein advantageously reduces the amount of heated drum and tensioning devices required to draft and orient the fibers because pressure spinning naturally orients the fibers. Conventional fiber drawing and orientation and extrusion may require up to 3 levels of space. Pressure spinning is a single small size quiet device and requires very little energy. In the case of some fibers, the requirements may include heaters and tensioning devices. This is also contemplated and may include position or post processing between the collector and the spinneret. However, it is envisaged that the post-processing will be smaller than the current manufacturing requirements. similar In the nanofiber mat, the larger fiber pressure spinning mat can be directly twisted into a yarn. This twisting causes entanglement similar to self-cutting fiber spinning. If a higher degree of fiber orientation is desired, the mat can be carded as previously described.

11 through 21 show alternative examples of pressure jet spinning or other jet extrusion systems having a fiber collection system that collects diatomaceous earth or other filaments or fibers and winds them into continuous filaments or fibers. (System components are not meant to be used for conceptual description and are not intended to be to scale). As the jet 215 of the fiber forming material exits the orifice of the spinneret and centrifugally stretches the filament or fiber, and it aligns the fibers and provides strength by orienting the polymer chains within the fibers. This is similar to other jet extrusion methods disclosed herein. For example, the jet may comprise a blend of fibers selected from the group consisting of polyester, nylon, natural fibers (eg, cellulose), biological (naturally derived, synthetic) fibers, biocomponent fibers, and unique cross-section (core sheath) fibers. The materials of the group and any other materials disclosed or covered herein. The fiber forming material can include dispersed particles to, for example, increase fiber efficiency or electrical conductivity. Any fiber forming material can be collected as continuous filaments using a myriad of collection methods. Several representative methods are outlined below. However, such embodiments are not intended to be exhaustive. Those skilled in the art will recognize from the teachings herein that a variety of techniques and devices can be employed to collect the diatomized soil fibers.

Spinning heads that use jets or streams of material under centrifugal force provide similarities to cotton candy production. As used herein, "flow" or "jet" means a fiber or filamentary stream of material in any state (eg, liquid, softened or solid). An example of a solids flow of material will be a moving yarn that is pulled to the spool or pulled from the spool. As used herein, "structure" or "strand" means a solid phase fiber or a filamentary material in the context of a fiber. In the processing steps covered herein, the structure or strand may exist dynamically, such as in a streaming state, or it may exist statically.

In the marshmallow manufacturing machine, the strand of cotton candy fiber is made by self-collecting The spinning of the spinning head is formed by liquid spinning. The collector in which the spinneret is centered is substantially a circular bowl. The strands are collected in a vertical wall around the collector. A winder, which is an elongated article, such as a paper cone, is then moved in a circular path along the collector wall, wherein the longitudinal axis of the winder is oriented parallel to the wall of the collector. As the winder surrounds the wall, it pulls the fiber strands deposited on the wall. As the winder is wrapped around the wall, it also rotates about its longitudinal axis. This additional rotation causes the fibers to be wound around the winder to produce a uniform deposition of the fiber strands around the winder. In the case of marshmallows, the fibers are weak, short, viscous and are wound without tension. Therefore, the method is not intended to be used when a tight winding of the fibers is required or when the fibers are not viscous and the walls from which the fibers are deposited are attracted to the winder. Moreover, the marshmallow manufacturing machine process does not provide a solution to how to wind the mat of collected fibers into a continuous filament form to better, but not necessarily achieve, the problem of tight winding and entanglement under a certain tension.

In the following examples, a collection and winding process for use with pressure spinning or other spinning techniques for continuous fibers for fabric applications is disclosed. The subject matter of the present invention overcomes the deficiencies of the simple marshmallow manufacturing machine process, which is not related to the possibility of reducing the marshmallow pad to a wavy filament form under a certain tension.

18 through 23 show examples of collection systems including one or more collectors 18, 118, 218, 318, 418, 518, and 618, each having a surface that receives a stream of material from a spinneret. In accordance with the inventive subject matter, the collector 318 can be associated with the spinning orifice 216 of the spinneret and rotate in unison with the spinning orifice 216 of the spinneret. Alternatively, the fixed non-track collector can be secured and positioned below the geometric center of the spinning head 212 of the spinning system. Coordinating the relative spinning rate of the collector and the spinneret such that the filamentary fibers 215 are wound onto the collector within the following range of tension: (1) achieving the desired tightness state without the need to break the fiber into a fractured or deformed state; 2) Avoid the filaments formed or When the formed filament is wound, the flow is slow, so as to prevent the formed filament or the formed filament from being wound and broken or deformed. In addition to the collector, the collection system may also include other components, such as heaters and rollers between the spinneret and the collector or subsequent fiber processing to help manage tension and flow or filament orientation. The collection system will naturally include other components (not shown), such as an electric motor that drives the collector or other components, determining the rate of rotation of the spin pack or the flow rate from the jet outlet or measuring the strain or load of the material or component. Sensor or register. The system may also include manual and/or computer controls, such as a microprocessor and memory with stored programs for managing the ratio of the spinning and strain or load relative rates of the filaments being formed or formed.

Figures 18 through 19 are schematic side and top views of a possible collection system for the flow of diatomaceous earth-forming fibrous material and/or other fibrous materials extruded from a given spinneret. In this case, a collector 318, such as a drum or cylinder, surrounds the spinneret at a distance from the exit or the cymbal of the spinneret (which can be placed on the spinneret or along the circumference of the spinneret). Rotate in the form of a track. The collector is sufficiently spaced from the spinneret to allow proper extrusion and drafting of the filaments or fibers via a rotating centrifugal force. The radial and linear distance of the collector from the exit weir is determined by the size of the exit weir and the diameter of the fibers produced. This is because the injection of the fiber forming material requires a certain distance of inertial drafting to properly orient the polymer chain within the shaped fibers. Other parameters to consider are the properties of the extruded material. For example, the viscosity of the solution and the alignment of the polymer chains within the fibers are factors that affect the extendable distance of the fibers using inertial forces. Reducing the effect of the winding of the fibers and the eddy currents caused by the rotating collector are also factors to be considered. Any of the foregoing factors may be considered and experienced by those skilled in the art without undue experimentation. Thus, as discussed below, the proper spacing of the collector from the spinneret and the relative rate of rotation of the collector to the spinneret can be determined empirically or otherwise.

Referring to the system of Figures 18-19, the collector 318 is external to the spinneret 212 The circumference is spaced apart and runs around the spinneret track. The collector rotates about its own longitudinal axis while it is running around the spinneret track. The rotating shaft of the collector is parallel to the axis of rotation of the spinning head. The axial rotation of the collector causes the fibers 215 to be tightly wound to the collector and coalesced around the collector, the filaments or fibers being oriented generally parallel to each other. In this embodiment, the rotary spinneret and collector can be moved relative to one another in the same plane or in a plane parallel to the spinneret. In this embodiment, the collector operates around a fixed spinner head track (other than axial rotation). Alternatively, the spinneret can be orbited around a collector (which can be fixed). Any track configuration allows a uniform fiber winding distance through the track. The rate of rotation of the collector (rpm) can be calculated or determined based on the particular filament or fiber material and diameter. The collector rotates about its own axis to create tension in the winding of the fibrous material. The fiber strength will determine the amount of tension required to properly wind the filaments or fibers around the collector. If the run/minute of the collector is too fast and exceeds the tensile strength of the fibers or filaments, fiber breakage can occur. If the revolution/minute is too slow, the filaments or fibers may be rotated. This can cause weakness in the filaments or fibers or it can break filaments or fibers. As indicated above, the collection conditions can vary from material to material but can be established empirically. Those skilled in the art will appreciate that the mechanisms required to direct the fibers onto the winding collector are numerous and encompass all such mechanisms, even if not explicitly disclosed herein. The revolutions of the spin/minute by the relaxation of the filament or fiber starting speed equal to the inertial extension of the exit from the spinneret can be achieved by other systems than the systems of Figures 18-19.

While the spinneret can orient the fibers in the same direction, directional air or other gas streams can be used to direct the flow of material extruded from the spinneret or even the stationary extrusion device. Mechanisms for directing airflow include positive and negative pressure systems such as fans, vacuum, and pressurized gas sources. The gas flow can be directed at any desired angle relative to the material flow to redirect the flow to the desired path and orientation. For example, the material flow can be directed onto a continuous belt. In this specific example and any other specific examples, movable The flat surface can be part of a continuous belt system that feeds the fibrous material into a drum or winder or other processing system.

Algae soil structure for footwear and other applications

The subject matter of the invention also relates to the use of diatomaceous earth particles in an external grounded surface of a sole unit. Alfalfa has a hardness of about 7 on a Mohs scale compared to diamond (9), granite (7) and quartz (7). Because of this hardness, and because it is relatively non-brittle, the particles can be used to improve traction on particularly smooth surfaces such as icy ground or wet ship decks, skateboards, surfboards, and the like.

As seen in Fig. 20, the universal shoe 300 generally has a sole unit 310 and a fully or partially enclosed upper 312 that is secured to the sole unit. In the case of sports and some outdoor shoes, the "sole unit" may generally comprise an energy absorbing and/or returning midsole; for surface contact and abrasion and/or traction of the outsole material; or providing A single unit that functions as a midsole or outsole. The sole unit may also include an in-sole that fits between the user's foot and the midsole or other sole assembly. While the sole unit will generally extend along the length of the shoe, the sole unit may also include units that extend a smaller area (such as only the forefoot or hindfoot portion) or some other area of smaller length or width. The foot-facing side of the sole unit has a foot platform portion. The term "foot-platform portion" as used herein generally refers to a portion of a sole unit that supports the foot formed by the upper surface of the sole unit.

In some aspects, the subject matter of the present invention pertains to shoes having diatomaceous earth particles D as previously described herein embedded or bonded to the bottom surface thereof. Depending on the amount of surface area to be covered and the size of the particles used, typically at least 100, 1,000, 10,000, 100,000 or 1,000,000 or more than 1,000,000 of such particles can be used. Depending on the particle size and the blend of fine, medium and coarse grain sizes, the coverage can be referred to as any area, toe, forefoot with a 10% coverage to 100% coverage and a thickness of approximately 10 microns to 2 mm. , middle of the foot, heel.

By exposing the particles to the surface of the base outsole material, it engages the ground and enhances traction during use. By creating a layer of particles through the normal depth of wear of the outsole, the particles will continue to be exposed while the outsole is worn during use.

A variety of different designs and materials can be used in the construction of outdoor shoes. For example, the shoe outsole can be made from any of a variety of different materials, including rubber-like materials (eg, cured natural rubber, thermoplastic rubber (TPR) or any other synthetic rubber), synthetic leather, ethylene vinyl acetate (EVA) ), polyurethane elastomer, polyvinyl chloride (PVC), any other plastic material and/or any other suitable material. Outdoor shoes can be at least 1⁄4 inch thick, Thick or 1⁄2吋 thick outsole. The diatomaceous earth particles may be completely or partially distributed through the thickness of the outsole. For example, it can be via only 1%, 2%, 3%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, The 60%, 65%, 70%, 75%, 80%, 90%, 95% or complete to 100% outsole thickness is distributed in a given portion of the outsole. In some embodiments, the outsole has a diatomaceous earth portion in the front and/or rear foot portions of only the outsole (Fig. 21). The thickness of the algae soiled outsole or portion thereof need not be uniform and may vary. For example, the outsole can be tapered gradually, from the low wear portion of the outsole to the high wear portion becoming thicker. As an example, the midfoot portion may have very small or no thickness diatomaceous earth particles, while the forefoot and/or hind foot may have relatively high thickness particles.

The diatomaceous earth particles may be dispersed in the raw material of the outsole material, followed by formation of an outsole. The feedstock can be a granule, a liquid or a melt, as discussed above in combination with the fibers. The material can then be molded or cut into an outsole shape using various known techniques for molding thermoplastic or rubbery materials. Such techniques include, for example, injection molding or compression molding. The dispersion of diatomaceous earth can be obtained by some forming stages The blending, kneading, pressing or otherwise processing the diatomaceous earth into a raw material or forming or partially forming an outsole or an outsole substrate is produced. For example, a sheet of rubbery outsole material can be melt softened and the particles processed into a softening material. The softened material will fuse around the particles after cooling.

The algae soiled outsole portion generally, but not necessarily, has a homogeneous distribution of particles. This portion may incorporate from 0.1 wt% to 5.0 wt% or more than 5.0 wt% of the diatomaceous earth particles. It is believed that for a given squared coverage of the outsole, any given grain size or combination of grain sizes will cover at least 10% surface area per square inch to 100% area per square inch. In view of wear, the particles should provide coverage at depths from 10 microns to 2 mm or greater than 2 mm.

Sand can be a combination of quartz, feldspar, mineral fragments, volcanic rock fragments, sedimentary rock fragments and metamorphic rock fragments, most of which are quartz; SiO ₄ minerals. All the requirements and benefits of sand are naturally found in the diatomaceous earth. It is naturally found that the diatomaceous earth particles have an irregular shape. Grinding diatomaceous earth provides even more asymmetry to provide better traction control. Algae can be treated as hydrophobic and will increase traction under wet conditions.

Advantageously, for traction control of footwear under wet, dry, icy, and rocky conditions, the diatomaceous earth particles are natural materials that provide a harder and more desirable alternative to current sand and ceramic options. The diatomaceous earth particles are 80-90% cerium oxide, and the remaining composition is attributed to the clay material. In addition, it is a hard cerium oxide material that absorbs twice its weight in water and still has the characteristics of dry diatomaceous earth particles. In addition, the diatomaceous earth particles are highly porous and naturally have an irregular shape. In addition, it can withstand heat treatment, can be easily made hydrophobic, and can be ground to a fine grain size as well as a rough size.

The amount of traction depends on the coating method, the level of particles applied, the particle density and the predetermined surface used in the case of footwear, as well as environmental conditions (eg, temperature, snow, ice, water). The predetermined surface used may be, for example, rock, ice, pavement, sandstone, boat, surfboard, vertical pulp board, and the like.

The coverage of the outsole is envisaged as a 10% surface coverage for the light-drawn diatomaceous earth particles and as high as 100% in the case of high traction, wetting and icing. Different percentage gradations are envisaged for different applications and for use in gloves as discussed below, where high particle density may not be desirable because flexibility may be reduced. The particle grain size can be a blend of diatoms with sand or sand material. The blended particles can be selected from the group consisting of fine grades (about 300 microns and less), intermediate grades (about 300-600 microns), and coarse grades (about 600 microns) and higher order particles. For wet conditions or warm ice conditions (>20 Fahrenheit), fine grade algae will be used.

The subject matter of the present invention is also directed to novel constructs in which agglomerates of diatomaceous earth particles are produced to increase the effective size of the diatomaceous earth particles beyond their natural size range. Discrete agglomerates of one or more particles can be obtained by creating a dispersion of greater than 5% by weight diatomaceous earth as a base material, such as the thermoplastic materials discussed above. The size of the coalesced particles will increase as the weight % of the diatomaceous earth increases. Dispersants are known to be used to manage the level of particle agglomeration.

Similar to airport runways, shoes used for ice outsole, for alpine and glacier elevations, or where coarse temperatures are used anywhere below 15 degrees Fahrenheit. For rock and ice traction, a coarser grade can be used, which can include particles of 2300 microns or higher.

The blend is ideal for a multipurpose traction rubber outsole. In addition, the rubber outsole may have a change in coverage, wherein the algae are placed in a majority of a region; different grain size blends, percentages of surface area coverage, and use of any combination of forefoot to toe or heel or portion are used. / or the density of the algae layer (10 microns - 2mm).

The application of diatomaceous earth can be simply done with diatomaceous earth (pure or blended as discussed above) The bottom of the compression mold that coats the outsole or other structure. Here, rubber or other molding material is subsequently injected, and the diatomaceous earth is fused to the surface, which may be the ground-facing surface of the outsole.

In another method, the diatomaceous earth may be incorporated into a masterbatch blend of rubber or other forming material. In another method, the diatomaceous earth may be applied to the outsole or other structure by rolling, brushing, spraying, aerial spreading, or other coating methods after forming the outsole or other structure.

In addition to traction, diatomaceous earth can also be used to provide wear resistance to the surface of the building body. For example, the bottom of the baggage, gear bag or other bag or carrier may be coated with diatomaceous earth to provide abrasion resistance. In apparel, high wear areas of the garment, such as the shoulder, elbow, knee or hip regions, may be coated with diatomaceous earth particles. In such cases, the carrier (such as a polyurethane) or printing process can be used to coat a thin (eg, 10 micron to 2 mm) diatomaceous earth coating, either alone or in any combination of fine, intermediate or coarse grades. Floor. Printing techniques can also be used to deposit diatomaceous earth particles on the structure to provide wear resistance or other characteristics. In the case of printing and coating of clothing and gear bags, luggage, etc., 10%-100% surface coverage will generally be suitable. Similar to the requirements of the runway surface, the particles can be used to absorb water and drain for better traction. If desired, the diatomaceous earth particles can be modified or treated to be hydrophobic to resist moisture absorption and maintain high traction for any application.

As an example of a heterogeneous distribution, the diatomized soil portion may have a gradient distribution corresponding to high to low wear or traction regions.

The outsole may be a separate component of the assembly of sole unit components or it may be part of a single piece sole unit. For example, the EVA molded sole unit provides outsole and midsole functionality. The single piece sole can have a plurality of portions of hardness. For example, the ground-facing diatomaceous earth portion may have a higher, more wear-resistant base material and the foot-facing portion may have a softer, lower hardness.

In general, the sole unit (assembled or monolithic) portion used as an outsole will have a hardness of between 70 and 85 or about a value for a rubber using an Asker Durometer. In contrast, the midsole portion, if present, can have the same hardness or a relatively lower hardness of 50 to 60 or a value for an EVA using an Asker hardness meter.

The portion of the spirulina soiled portion of the sole unit does not have to completely cross the width and length of the algae. The algae soiled region may be only the forefoot portion 314 and the hindfoot portion 316, as seen in FIG. For example, the portion can be defined by a population of diatomaceous earth particles D that generally define a portion of the pattern of the outer sole. For example, as indicated in Figure 20, the diatomaceous earth portion can be composed of any one or more than one shape, such as a belt, a circle, a triangle, a curve, or any combination of shapes.

The diatomaceous earth sole unit can be used with any type of shoe where enhanced traction or slip resistance can be desired. Non-limiting examples include footwear for ice, climbing, athletics, fishing and trekking, and industrial footwear (eg, roofing footwear).

gloves

Similar to the friction enhancing application of footwear, the subject matter of the present invention can provide enhanced grip of the glove by diatomaceous earthing on the grip side of the glove. This can be done by using a diatomized earthy fabric or a rubbery material in the gripping area (eg, one or more fingers and/or palm areas). The fabric can be geotized as previously disclosed herein. Or the gripping area may be coated with or made of a rubbery or plastic material having algae particles. Figure 22 shows an example glove 400 having a gripping region 410 containing embedded diatomaceous earth particles D.

Similar to garment applications, in addition to or in addition to the algae soiling of the gripping area, the glove may also include providing moisture control in the glove, drawing moisture to keep away The earthworm layer of the kelp in the hands of the user. This layer can be part of an entire waterproof/breathable glove assembly similar to a 2L, 2.5L or 3L assembly in a garment.

For other applications, screen printing on fabrics can be used. For example, the diatomaceous earth is PU, preferably the water-based polymer can be printed on the design or specific part of the fabric with the algae screen.

Water repellency and soil repellency of diatomized soil surface

The Lotus Effect occurs when water encounters the structure of the microarray on the surface. It is well documented. See, for example, http://www.mecheng.osu.edu/nlbb/files/nlbb/Lotus_Effect.pdf.

In Figure 23, water droplets emerge from the surface of the hydrophobic diatomaceous earth particles embedded or otherwise applied to the surface of the substrate.

Due to their high surface tension, water droplets tend to minimize their surface by attempting to achieve a spherical shape. When in contact with the surface, the adhesion causes the surface to wet. Occurs completely or incompletely by wetting the visible surface structure and the fluid tension of the droplets. The reason for the self-cleaning property is the hydrophobic and water-repellent double structure of the surface. This allows the contact area and adhesion between the surface and the droplet to be significantly reduced, resulting in water repellency and self-cleaning processes. This layered double structure is formed in the characteristic skin layer (the outermost layer is called the stratum corneum) and the covering wax. The skin layer of the lotus plant has a mastoid having a height of 10 μm to 20 μm and a width of 10 μm to 15 μm, on which a so-called epidermal wax is applied. These superimposed waxes are hydrophobic and form a second layer of dual structure.

The hydrophobicity of the surface can be measured by its contact angle. The higher the contact angle, the higher the hydrophobicity of the surface. The surface with a contact angle <90° is called hydrophilic, and the surface with an angle of >90° is called hydrophobic. Some plants exhibit a contact angle of up to 160° and are referred to as superhydrophobic. This means that only 2-3% of the water droplet surface Contact occurred. Plants with dual structured surfaces (such as lotus) can reach a 170° contact angle, resulting in an actual contact area of droplets of only 0.6%. All of this leads to higher water repellency and self-cleaning effects. The dirt particles are obtained by water droplets on the surface of the substrate. If the water droplets roll off or shake off, the dirt particles on such contaminated surfaces are removed due to their adhesion to the water droplets being higher than their adhesion to the surface of the substrate. (Previous technical information is from http://en.wikipedia.org/wiki/Lotus_effect).

The diatomaceous earth particles can be arranged on the surface of the substrate to simulate the structure and contact angle of the lotus leaves as well as other superhydrophobic surfaces known in the art. For example, the parameters of the lotus effect surface mode are disclosed in U.S. Patent Nos. 3,354, 022, 6, 666, 036, and U.S. Pat. However, none of the aforementioned patents reveals or indicates the use of diatomaceous earth particles for surface topography. The subject matter of the present invention relates to innovative adaptations of surface topologies known to provide a lotus effect.

No. 3,340,422 describes a water-repellent surface having an inherent forward water contact angle of greater than 90° and an inherent receding water contact angle of at least 75° by creating a micro-rough structure in which the hydrophobic material has ridges and depressions. The average distance between the high portion and the low portion is no more than 1,000 microns, and the average height of the high portion is at least 0.5 times the average distance between them. The air content is at least 60% and, in particular, the fluoropolymer is disclosed as a hydrophobic material. No. 6,660,363 describes a self-cleaning surface of an article made of a hydrophobic polymer or a permanently hydrophobic material having an artificial surface structure with ridges and depressions. The distance between the ridges is in the range of 5 μm to 200 μm, and the height of the ridges is in the range of 5 μm to 100 μm. At least the ridge is composed of a hydrophobic polymer or a permanently hydrophobic material. The bulge cannot be passed through a water or aqueous cleaner by attaching PTFE particles (7 microns in diameter) to the surface of the polymer-containing adhesive film and curing the structure or by hot pressing to imprint the polymer surface by using a fine mesh screen. Wetting. As a possible option, the diatomaceous earth particles can be imprinted onto the surface of the substrate in a similar manner. To impart hydrophobicity to the algae without clogging the pores, typical bath applications can be used as well as gas/plasma deposition. Gas phase/plasma deposition allows the surface to be coated with a fluorinated and non-fluorinated water repellent finish.

The algae powder may be treated as is, or the algae agglomerate may be treated in powder form and subsequently used for surface coating to abrade and tow the control surface.

A lotus effect surface pattern based on a bulge having a primary structure and a secondary structure is disclosed in US 8486319. This patent discloses the creation of a plurality of pits and cracks or protrusions in at least a portion of the outer surface of the random and/or even distribution of the substrate to form the primary structure of the lotus effect surface pattern. This patent discloses the shape, size and number of populations such as recesses, pits, cracks, depressions, such as the topography of the diatomaceous earth particles and the surface of the associated substrate, which is capable of trapping air and thus providing a lotus effect. A micro-sized surface structure, that is, a surface-exposed diatomaceous earth particle having a density of 25 to 10,000 sites per square millimeter, or 100 to 5,000 sites per square millimeter, or 5 to 100 per millimeter The range of loci, or approximate values. The surface sites may range from a depth of 5-100 microns or a depth of 10-50 microns; or a diameter of 5-100 microns or a diameter of 10-50 microns, or an approximate value. The sites can be separated by 5-100 microns or separated by 10 microns to 50 microns or approximately. Any of the constructs covered herein can be formed to provide a lotus effect by the algae geochemistry of the surface of the construct in the lotus effect topology.

Definition (as described in the literature for the outdoor and textile industries): Waterproof/breathable (composite fabric): A fabric (knitted or woven) composite that is water-resistant to a certain pressure as defined by different standards, but Breathable, as measured by different standards, allows moisture to pass through the composite. The composite material may comprise a fabric layer and a waterproof gas permeable membrane (defined as a two-layer waterproof and breathable composite material), or a waterproof gas permeable membrane may be sandwiched between two fabric layers (defined as a three-layer waterproof and breathable composite) material). Waterproof and breathable composite material in 2.5 layers In this case, the membrane typically has an imprint applied to the surface of the membrane opposite the side of the outer fabric. This imprint can be color, design, and/or include functional particles in any pattern. The fabric layer can be a woven or knitted structure of any fiber type (natural, synthetic, biological, biodegradable) or a blend of any fiber type. Use seam tape to seal all seams to ensure water resistance.

Waterproof/breathable diaphragm: Flexible material that is (1) waterproof and (2) moisture repellent according to selected standards. The membrane can be hydrophilic, hydrophobic, monolithic or microporous. The two-component membrane combines two layers, such as a GORE-TEX ePTFE membrane and another layer of material.

Air permeability: The ability of a fabric, membrane, or composite to allow air to penetrate a material; measured in cubic centimeters per minute.

Water Vapor Permeability / Vapor Permeability: A fabric, waterproof/breathable membrane or composite that allows moisture (liquid or water vapor) to pass through the material.

Hard shell (2L, 2.5L, 3L): A waterproof, breathable composite consisting of multiple layers 2, 2.5 or 3L that achieve a higher degree of wind resistance. The outer layer is typically a more durable material such as a polyester or nylon fabric. Typical fabrics shrink to prevent cracking.

Soft shell: A fabric composite that has high water resistance but is focused on wind blocking. Wind clogging can be achieved using a waterproof, gas permeable membrane (which is sandwiched between two fabric layers) or by attaching two fabrics or substrates together using an adhesive or glue. The glue is not air permeable, and therefore the air of the metering composite is infiltrated. Fabric fabrics are typically softer woven and knitted fabrics and are therefore referred to as soft shells. By manipulating the design features of each fabric composite, air permeability can range from 0 to 100% wind blockage.

Nanofiber: defined as a fiber having a diameter between 100 nm and 1000 nm. Nanofibers offer high surface area and unique properties at the nano level.

Non-woven: A fabric-like material made of fibers bonded together by a method other than weaving, such as chemical, heating, mechanical, or solvent methods. The fibers are entangled to create a network structure. The entanglement creates pores between the fibers, providing a degree of air permeability.

A person skilled in the art will recognize that many modifications and variations can be made in the details and materials and arrangements of the details and the details of the invention. It contains the spirit and scope of the scope of the patent application.

All patent and non-patent documents cited herein are hereby incorporated by reference in their entirety for all purposes.

As used herein, "and/or" means "and" or "or" and "and" and "or". In addition, any and all patent and non-patent documents cited herein are hereby incorporated by reference in their entirety for all purposes.

The principles described above in connection with any particular embodiment can be combined with the principles described in conjunction with any one or more of the other embodiments. Therefore, the present embodiments are not to be construed as limiting, and, after reviewing the present invention, one of ordinary skill in the art will appreciate a wide variety of systems that can be designed using the various concepts described herein. In addition, it will be appreciated by those skilled in the art that the exemplified embodiments disclosed herein are susceptible to various configurations without departing from the principles of the invention.

The previous description of specific examples of the invention is provided to enable any person skilled in the art to make or use the invention. Various modifications of the specific examples will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Therefore, the claimed invention is not intended to be limited to the specific examples shown herein, but should be consistent with a comprehensive scope consistent with the language of the claimed application. References to elements in the singular (such as the use of the articles "a" or "an") are not intended to mean "one and only one" unless otherwise specified.

All structural and functional equivalents to the elements of the specific embodiments described in the Detailed Description of the invention are intended to be In addition, nothing disclosed herein is intended to be dedicated to the public, regardless of whether the disclosure is explicitly recited in the scope of the patent application. Under U.S. Patent Law, any element of the patent application scope is not to be construed as a "method plus function" patent application unless the element explicitly uses the phrase "method for" or "step for".

Claims (30)

A diatomaceous earth structure comprising: a first side comprising a layer of fusible material; and a second side having a discrete lattice structure, the second side being adjacent and coextensive with the first side, The layer and the discrete lattice structure are melted in a single structure; wherein the lattice structure comprises a plurality of diatomaceous earth fibers, filaments or yarns, and each of the diatomized earth fibers, filaments or yarns are embedded in a plurality of diatomaceous earth particles And wherein the diatomaceous earth particles cover the selected portion of the surface region of the diatomaceous earth structure. The diatomaceous earth structure according to claim 1, wherein the diatomaceous earth particles substantially uniformly cover 1-10% of the surface area of the diatomaceous earth structure. The diatomaceous earth structure according to claim 1, wherein the diatomaceous earth particles substantially uniformly cover 10-30% of the surface area of the diatomaceous earth structure. The diatomaceous earth structure according to claim 1, wherein the diatomaceous earth particles substantially uniformly cover 30% or more of the surface area of the diatomaceous earth structure. The diatomaceous earth structure of claim 1, wherein the fusible material comprises a thermoplastic material. The diatomized earth structure according to claim 1, wherein the lattice structure is formed by a plurality of woven loop structures of a plurality of latitudes and a plurality of pairs of filaments in the warp, the filaments At least one is a fusible material that forms the layer. The diatomaceous earth structure according to any one of the items 1 to 5, wherein the diatomaceous earth particles are present in the diatomaceous earth structure by 0.1% to 5% by weight of the fiber. In fiber, filament or yarn. The diatomaceous earth structure according to any one of claims 1 to 5, wherein the diatomaceous earth particles have an average size of from 1 μm to 3 μm. The diatomaceous earth structure according to any one of claims 1 to 5, wherein the diatomaceous earth particles have an average size of less than 5 μm. The diatomaceous earth structure according to any one of claims 1 to 5, wherein the diatomaceous earth particles have an average size of more than 200 μm. A diatomized earth structure as claimed in claim 1, wherein the fusible material in the layer is completely melted to provide a completely molten structure of the layer. A diatomaceous earth structure according to claim 1, wherein the lattice structure comprises a woven structure. A diatomized earth structure according to claim 1, wherein the lattice structure comprises a knitted structure. A diatomaceous earth structure as claimed in claim 1 wherein the fusible material in the layer is partially melted to provide a partially melted structure of the layer. A diatomaceous earth structure according to claim 1, wherein only the first side or the second side is embedded with diatomaceous earth particles. The diatomaceous earth structure according to claim 1, wherein the first side and the second side are both embedded in diatomaceous earth particles. A diatomaceous earth structure as claimed in claim 1 wherein at least some of the diatomaceous earth particles have been chemically modified or treated to provide an intrinsic function of the particles. The diatomized earth structure according to claim 1, wherein the diatomaceous earth fibers, filaments or yarns are formed by jet extrusion of the mixture of the diatomaceous earth particles and the polymer raw materials. to make. A diatomaceous earth structure as claimed in claim 17 wherein the diatomaceous earth particles have been chemically modified or treated such that they are relatively more hydrophobic than their inherent state. The diatomized earth structure according to the first aspect of the patent application, comprising a product having a first diatomized soil portion and a second diatomized earth portion, the first diatomized earth portion and the second diatom The soiled portions are joined together at the edge regions, wherein the product comprises one or more of the following: garments; footwear; gloves; headwear; tents; backpacks; containers or carriers of the nature of luggage and other articles; Bedding; tablecloth; linen; car seat cover; tarpaulin; towel; medical fabric; geotextile; filter media; and agricultural fabric. A diatomaceous earth structure according to claim 1, wherein one or more of the diatomaceous earth fibers, filaments or yarns are formed from a plurality of thermoplastic materials. The diatomized earth structure according to claim 1, wherein one or more of the diatomized earth fibers, filaments or yarns have a two-component configuration, wherein one component is formed from the first thermoplastic material And another component is formed from the second thermoplastic material. The diatomized earth structure according to claim 1, wherein the first group of the diatomized earth fibers, filaments or yarns are formed from the first thermoplastic material, and the diatomized earth fibers and filaments are Or a second group of yarns is formed from the second thermoplastic material. The diatomaceous earth structure according to claim 1, wherein the diatomaceous earth fiber, filament or yarn is an elastomer. A diatomaceous earth structure according to claim 1, wherein the diatomaceous earth fiber, filament or yarn can be returned to the original shape after being stretched. A diatomized earth structure according to item 1 of the patent application, which comprises a yarn or another multifilament combination The ratio of the number of denier/filaments of the multifilament structure is 0.25 to 2. For example, the diatomaceous earth structure of claim 26, wherein the ratio is 1.0. The diatomized earth structure of claim 1, wherein the lattice structure has a diatomized soil surface topology configured to provide a lotus effect. The diatomized earth structure of claim 1, wherein the lattice structure comprises a diatomized soil surface comprising a base material and embedded or coated to the base material and exposed to the base material a plurality of discrete diatomaceous earth particle agglomerates on the surface. The structure of claim 29, further comprising a plurality of non-diatomite sand or sand embedded or coated to the base material and exposed to the surface of the base material.