Note: Descriptions are shown in the official language in which they were submitted.
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FILAMENTS WITH IMPROVED LUSTER
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application
No.63/116,334,
filed November 20, 2020, the content of which is incorporated herein by
reference in its
entirety.
TECHNICAL FIELD
This disclosure relates to polymeric filaments, and more particularly to multi-
component filaments with enhanced luster that may find use in the production
of yarns.
BACKGROUND
Within the textile industry. and particularly the carpet industry. consumers
increasingly demand products that show more interesting and complex visual
properties.
The luster of the filaments used in manufacture is one property that impacts
the visual
aspect of textile products. Typically, manufacturers adjust the luster
properties of a filament
by adjusting the composition or shape of the filament. While products having a
higher luster
may be desirable for their visual properties, they may be considered
impractical in some
applications due to their propensity to more readily show soiling compared to
more matte
products. In many applications, a delusterant such as titanium dioxide may
instead be added
to provide a more matte finish to the product. Further, many filaments that
naturally have
higher luster, such as silk, are also more prone to wear from use. Thus, there
is a clear need
for new products for use in textiles that show enhanced luster while also
showing enhanced
strength and stain resistance properties.
SUMMARY
The present disclosure provides yarns and multi-component filaments having a
plurality of solid particles dispersed throughout a portion of the filaments.
Inclusion of solid
particles through a portion of the filaments, in particular translucent or
transparent particles
such as glass flakes or mica, allow for differing visual properties in
products formed from
the filaments, such as an increased luster, while maintaining desirable
physical properties
such as strength or abrasion resistance.
According to a first aspect, a multi-component filament is provided comprising
a
first component comprising a first polymer and a second component comprising a
second
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polymer and a plurality of solid particles dispersed within the second
polymer, wherein the
second component forms at least 50 percent of an external (or outermost)
surface area of the
multi-component filament. In some embodiments, the multi-component filament is
a
bicomponent filament.
In some embodiments, the first component comprises a core and the second
component comprises a sheath, wherein the sheath encapsulates the core.
In some embodiments, the solid particles are evenly dispersed in the second
polymer.
In some embodiments, the first component may further comprise a plurality of
solid
particles dispersed in the first polymer, the plurality of solid particles
having a concentration
by volume in the first polymer that is less than a concentration by volume of
the particles of
the second polymer. In some embodiments, the solid particles are evenly
dispersed in the
first polymer.
In some embodiments, the solid particles may be transparent or translucent. In
some
embodiments, the solid particles may comprise glass flakes. In some
embodiments, the
glass flakes have an average particle diameter ranging from 5 microns to 35
microns. In
some embodiments, the glass flakes have an average thickness ranging from 0.5
microns to
8 microns. In some embodiments, the glass flakes are surface treated with a
coating, for
example a silane coating. In some embodiments, the glass flakes may be present
in a
concentration of at least 10% by volume within the second polymer.
In some embodiments, a luster of the multi-component filament is higher than
that
of a multi-component filament that comprises the first polymer and the second
polymer
without the solid particles.
In some embodiments, the first polymer and the second polymer are different
polymers. In some embodiments, the first polymer and the second polymer are
the same
polymer. In some embodiments, the first polymer and the second polymer may
each be
independently selected from a polyamide (for example, polyamide 6 or polyamide
6,6), a
polyester (for example, polyethylene terephthalate or polytrimethylene
terephthalate), or a
polyolefin (for example, polyethylene or polypropylene).
According to a second aspect, a yarn is provided comprising a plurality of
multi-
component filaments as described herein.
According to a third aspect, a yarn is provided comprising at least one of a
first
filament and at least one of a second filament, wherein the first filament
comprises a first
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polymer, and wherein the second filament comprises a second polymer and a
plurality of
solid particles dispersed within the second polymer.
The details of one or more embodiments of the disclosure are set forth in the
accompanying drawings and the description below. Other features, objects, and
advantages
of the disclosure will be apparent from the description and drawings, and from
the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Example features and embodiments are disclosed in the accompanying drawings.
However, the present disclosure is not limited to the precise arrangements
shown, and the
drawings are not necessarily drawn to scale.
FIG. 1 illustrates a perspective view of an elongated filament according to
one
embodiment.
FIG. 2 illustrates a cross-sectional view of a filament according to another
embodiment.
FIG. 3 illustrates a cross-sectional view of a yarn according to one
embodiment.
FIG. 4 illustrates a cross-sectional view of a filament according to one
embodiment.
FIG. 5 illustrates a cross-sectional view of a filament according to another
embodiment.
FIG. 6 illustrates a cross-sectional view of a filament according to another
embodiment.
FIG. 7 illustrates a cross-sectional view of a filament according to one
embodiment.
FIG. 8 illustrates a cross-sectional view of a filament according to another
embodiment.
FIG. 9 illustrates a cross-sectional view of a filament according to another
embodiment.
FIG. 10 illustrates a cross-sectional view of a filament according to another
embodiment.
FIG. 11 illustrates a cross-sectional view of a filament according to another
embodiment.
FIG. 12 illustrates a cross-sectional view of a filament according to another
embodiment.
FIG. 13 illustrates a cross-sectional view of a filament according to another
embodiment.
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FIG. 14 illustrates a cross-sectional view of a filament according to another
embodiment.
DETAILED DESCRIPTION
The compositions and methods of the appended claims are not limited in scope
by
the specific compositions and methods described herein, which are intended as
illustrations
of a few aspects of the claims, and any compositions and methods that are
functionally
equivalent are intended to fall within the scope of the claims. Various
modifications of the
compositions and methods in addition to those shown and described herein are
intended to
fall within the scope of the appended claims. Various modifications of the
compositions and
methods in addition to those shown and described herein are intended to fall
within the
scope of the appended claims. Further, while only certain representative
compositions and
method steps disclosed herein are specifically described, other combinations
of the
compositions and method steps are also intended to fall within the scope of
the appended
claims, even if not specifically recited. Thus, a combination of steps,
elements, components,
or constituents may be explicitly mentioned herein; however, other
combinations of steps,
elements, components, and constituents are included, even though not
explicitly stated.
The term "comprising" and variations thereof as used herein is used
synonymously
with the term "including" and variations thereof and are open, non-limiting
terms. Although
the terms "comprising" and "including" have been used herein to describe
various
embodiments, the terms "consisting essentially of' and "consisting of' can be
used in place
of "comprising" and "including" to provide more specific embodiments of the
invention and
are also described. Other than in the examples, or where otherwise noted, all
numbers
expressing quantities of ingredients, reaction conditions, and so forth used
in the
specification and claims are to be understood at the very least, and not as an
attempt to limit
the application of the doctrine of equivalents to the scope of the claims, to
be construed in
light of the number of significant digits and ordinary rounding approaches.
As used in the specification and the appended claims, the singular forms "a",
"an"
and "the" include plural referents unless the context clearly dictates
otherwise.
-Optional" and "optionally" means that the subsequently described event or
circumstance may or may not occur, and that the description includes instances
where said
event or circumstance occurs and instances where it does not.
Yarns and multi-component filaments having a plurality of solid particles
dispersed
throughout a portion of the filaments are described herein. Inclusion of solid
particles
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through a portion of the filaments allows for differing certain properties in
products formed
from the filaments while maintaining desirable physical properties such as
strength or
abrasion resistance. For example, including translucent or transparent
particles, such as
glass flakes or mica, may differ the visual properties, such as providing an
increased luster.
And, in other implementations, opaque solid particles may be included through
a portion of
the filaments to create a different property for a product formed with the
filament.
Thus according to a first aspect, a multi-component filament is provided
comprising
a first component comprising a first polymer and a second component comprising
a second
polymer and a plurality of solid particles dispersed within the second
polymer, wherein the
second component defines at least 50 percent of an external (or outermost)
surface area of
the multi-component filament. In some embodiments, the multi-component
filament is a
bicomponent filament.
A cross-sectional shape of the multi-component filaments described herein may
be
round or may have other shapes, such as octalobal, delta, sunburst (also known
as sol),
scalloped oval, trilobal, tetra-channel (also known as quatra-channel),
kidney, scalloped
ribbon, ribbon, starburst, semicircular, and the like. The cross-sectional
shape refers to the
shape of the filament as viewed in a plane that extends perpendicular to a
central axis of the
filament (e.g., an end view of the filament). The filaments may be solid,
hollow, or multi-
hollow (e.g., defining one or more axial voids therethrough).
FIGS. 1-2 and 4-14 illustrate cross-sectional views of bicomponent filaments
having
first and second polymers with different arrangements with respect to each
other, in
accordance with various embodiments of the first aspect. As shown, the second
component
comprises the second polymer and the plurality of solid particles dispersed
therein and
defines at least 50 percent of an external (or outermost) surface area of the
bicomponent
filament.
For example, FIG. 1 illustrates a bicomponent filament 120 that has a trilobal
cross-
sectional shape and includes a first component 122 and a second component 124.
The first
component 122 forms a core and is fully encapsulated by the second component
124. The
first component 122 includes the first polymer, and the second component 124
includes the
second polymer 124a and the plurality of solid particles 124b dispersed within
the second
polymer 124a. However, in other embodiments in accordance with the first
aspect, the first
component may not be fully encapsulated by the second component.
The bicomponent filament 130 shown in FIG. 2 also has a trilobal cross-
sectional
shape and includes first component 132 and second component 134. The second
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component 134 defines the trilobal shaped filament, and strands of the first
component 132
are coupled to distal ends of each lobe of the second component 134. The first
component
132 includes the first polymer, and the second component 134 includes the
second polymer
134a and the plurality of solid particles 134b dispersed within the second
polymer 134a.
The strands of the first component 132 have a circular cross-sectional shape,
but in other
embodiments in accordance with the first aspect, the strands of the first
component may
have another cross-sectional shape, such as any of those described herein.
FIG. 4 illustrates another example of a core/sheath bicomponent filament 10.
The
first component 12 comprises a core and the second component 14 comprises a
sheath that
fully encapsulates the core. The first component 12 and the second component
14 both have
circular cross-sectional shapes, and the first component 12 is centered within
the volume of
the second component 14. The first component 12 includes the first polymer,
and the
second component 14 includes the second polymer 14a and the plurality of solid
particles
14b dispersed within the second polymer 14a.
The core/sheath bicomponent filament 20 in FIG. 5 is similar to the filament
10 in
FIG. 4 in that the first component 22 is fully encapsulated by the second
component 24 and
components 12, 14 have circular cross-sectional shapes, but the first
component 22 is not
centered within the volume of the second component 24. The first component 22
includes
the first polymer, and the second component 24 includes the second polymer 24a
and the
plurality of solid particles 24b dispersed within the second polymer 24a.
The filaments 10, 20 have a circular cross-sectional shape, but in other
embodiments
in accordance with the first aspect, the filaments may have other cross-
sectional shapes,
such as those described herein. In addition, these filaments 10, 20 have a
circular shaped
first component 12, 22 as viewed in the plane that extends perpendicular to
the central axis
of the filament 10, 20, but the first components in other embodiments in
accordance with
the first aspect may have other cross-sectional shapes, such as those
described herein,
and/or may define one or more voids therethrough.
As another example, in the bicomponent filament 30 shown in FIG. 6, the first
component 32 and the second component 24 have a semi-circular shaped cross-
section and
are coupled together along flat surfaces of each component 32, 34 along a
plane that
includes the central axis of the filament. An external surface of the filament
30 has a
circular cross-sectional shape. The first component 32 includes the first
polymer, and the
second component 34 includes the second polymer 34a and the plurality of solid
particles
34b dispersed within the second polymer 34a. In other embodiments in
accordance with the
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first aspect, the volume of the second component 34 in the filament may be
increased
relative to the first component 32 such that the plane along which the
components are
coupled is spaced apart from the plane that includes the central axis.
As another example, a cross-sectional shape of the external surface of the
bicomponent filament 40 shown in FIG. 7 follows the external contour of the
number 8.
The first component 42 and the second component 44 each have a partial
circular cross-
sectional shape, and the components 42, 44 are coupled together along a plane
that includes
a chord of each cross-section, wherein the chord has a length that is less
than a diameter of
each component 42, 44. The plane in which the components 42, 44 are coupled
includes a
central axis of the filament 40. The first component 42 includes the first
polymer, and the
second component 44 includes the second polymer 44a and the plurality of solid
particles
44b dispersed within the second polymer 44a. In other embodiments in
accordance with the
first aspect, the plane in which the components 42, 44 are coupled may be
spaced apart from
the central axis of the filament.
The bicomponent filament 50 shown in FIG. 8 is similar to the filament 30
shown in
FIG. 6 but defines a circular shaped axial void 56 that is centered within the
filament 50, as
viewed in the plane that extends perpendicular to a central axis of the
filament 50. The first
component 52 includes the first polymer, and the second component 54 includes
the second
polymer 54a and the plurality of solid particles 54b dispersed within the
second polymer
54a.
The bicomponent filament 60 shown in FIG. 9 is similar to the bicomponent
filament 50 in FIG. 8, but the circular-shaped void 66 is not centered within
the filament 60.
The first component 62 includes the first polymer, and the second component 64
includes
the second polymer 64a and the plurality of solid particles 64b dispersed
within the second
polymer 64a.
The bicomponent filament 70 shown in FIG. 10 has a circular cross-sectional
shape
and defines an axial void 76 that is centered in the filament. The first
component 72 and the
second component 74 are arranged circumferentially around the central axis of
the filament
in alternating radial segments. For example, the filament 70 has sixteen
radial segments,
wherein the first component 72 and the second component 74 are alternately
arranged
around the central axis and void 76 of the filament 70. The first component 72
includes the
first polymer, and the second component 74 includes the second polymer 74a and
the
plurality of solid particles 74b dispersed within the second polymer 74a. In
other
embodiments in accordance with the first aspect, the filament can have four or
more
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alternating segments of the first and second components and no axial voids or
more than
one axial voids. For example, the bicomponent filament 80 in FIG. 11 shows an
example of
a bicomponent filament 80 having no axial voids but includes the
circumferential
arrangement of the first component 82 and the second component 84 in
alternating radial
segments. The first component 82 includes the first polymer, and the second
component 84
includes the second polymer 84a and the plurality of solid particles 84b
dispersed within the
second polymer 84a. In addition, the angle of each segment in the filaments
70, 80 are the
same, but in other embodiments in accordance with the first aspect, the angle
of each
segment may be varied relative to the other segments to increase the amount of
surface area
on the exterior surface of the filament.
The bicomponent filament 90 shown in FIG. 12 has a circular cross-sectional
shape
and includes alternating chord segments of the first component 92 and the
second
component 94. For example, the filament 90 has seven segments, but in other
embodiments
in accordance with the first aspect, the filament may have two or more
alternating chord
segments. The segments of filament 90 may have equal widths (as measured along
a
diameter of the filament 90) or the segments may have unequal widths to allow
one of the
components 92, 94 to occupy a greater surface area of the exterior surface of
the filament
90. The first component 92 includes the first polymer, and the second
component 94
includes the second polymer 94a and the plurality of solid particles 94b
dispersed within the
second polymer 94a.
The bicomponent filament 100 shown in FIG. 13 has a circular cross-sectional
shape
and includes a first component 102 and a second component 104. The first
component 102
is mostly encapsulated by the second component 104 but a portion of the first
component
102 extends to the exterior surface of the filament 100. The first component
102 includes
the first polymer, and the second component 104 includes the second polymer
104a and the
plurality of solid particles 104b dispersed within the second polymer 104a.
The bicomponent filament 110 shown in FIG. 14 has a circular cross-sectional
shape
and includes first component 112 and second component 114. The first component
112
comprises multiple strands extending axially through the second component 114,
and the
second component 114 encapsulates the first component 112 strands. Some of the
strands
of the first component 112 are circumferentially arranged in rings 112a-e, and
the rings
112a-e are radially spaced from each other and centered with respect to a
central strand
112e, which extends along the central axis of the filament 110. The first
component 112
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includes the first polymer, and the second component 114 includes the second
polymer 114a
and the plurality of solid particles 114b dispersed within the second polymer
114a.
In other embodiments according to the first aspect, the filaments may include
more
than two components and/or have any cross-sectional shape, including any of
the shapes
described herein.
A plurality of any of the multi-component filaments described herein may be
combined into a yarn according to the second aspect. For example, a plurality
of any of the
bicomponent filaments described herein may be combined into a yarn.
FIG. 3 shows a cross-section of filaments that are combined into a yarn 140
according to one embodiment in accordance with the third aspect. The yarn 140
includes a
first set of filaments 142 comprising (e.g., consisting of) the first polymer
and a second set
of filaments 144 comprising (e.g., consisting of) the second polymer having
solid particles
dispersed therein. Each filament has a tri-lobal shaped cross-sectional shape,
but in other
embodiments, one or more of the filaments may have other cross-sectional
shapes, such as
those described herein. The sets of filaments 142, 144 are combined together
to form the
yarn 140. The filaments from the second set of filaments define at least fifty
percent of the
external surface area of the yarn 140.
In addition, in other embodiments in accordance with the third aspect, the
filaments
in each set may be single component or have two or more components. And, in
other
embodiments in accordance with the third aspect, the cross-sectional shape of
the first
filaments and the second filaments can be the same or different, and the cross-
sectional
shape of filaments in each of set of filaments can be the same or different.
In some embodiments according to any of the first, second, or third aspect,
the first
polymer and the second polymer are the same, and in other embodiments, the
first polymer
and the second polymer are different.
Example systems for spinning the multi-component filaments described herein
includes at least two extruders (e.g., an extruder corresponding to each
component) and at
least one spin pack that includes at least one spinneret that defines openings
that form the
cross-sectional shapes of the filaments spun therethrough.
Any of the embodiments described below in the specification can be applied to
any
of the first through third aspects.
In some embodiments, the first polymer and the second polymer may
independently
comprise a polymer selected from a polyamide, a polyester, or a polyolefin. In
some
embodiments, the first polymer and the second polymer comprise the same
polymer. In
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some embodiments, the first polymer comprises a polyamide and the second
polymer
comprises a polyester. In some embodiments, the first polymer comprises a
polyamide and
the second polymer comprises a polyolefin. In some embodiments, the first
polymer
comprises a polyester and the second polymer comprises a polyamide. In some
embodiments, the first polymer comprises a polyester and the second polymer
comprises a
polyolefin. In some embodiments, the first polymer comprises a polyolefin and
the second
polymer comprises a polyamide. In some embodiments, the first polymer
comprises a
polyolefin and the second polymer comprises a polyester. In some embodiments,
the first
polymer and the second polymer each independently comprise a polyamide, either
the same
polyamide or two different polyamides. In some embodiments, the first polymer
and the
second polymer each independently comprise a polyester, either the same
polyester or two
different polyesters. In some embodiments, the first polymer and the second
polymer each
independently comprise a polyolefin, either the same polyolefin or two
different
polyolefins.
A polyamide is defined as a synthetic linear polymer whose repeating unit
contains
amide functional groups, wherein these amide functional groups are integral
members of the
linear polymer chain.
In some embodiments, the polyamide may have been formed by condensation
polymerization of a dicarboxylic acid and a diamine. Representative examples
of such
dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-napthalene
dicarboxylic
acid, 3,4' -diphenylether dicarboxylic acid,
hexahydrophthalic acid, 2,7-
naphthalenedicarboxylic acid, phthalic acid, 4,4' -methylenebis(benzoic acid),
oxalic acid,
malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid,
3-methyladipic
acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-
undecanedicarboxylic acid,
1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid,
hexadecanedioic acid,
docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid,
1,3-
cyclohexanedicarboxylic acid, 1,2-cyclohexanediactic acid, fumaric acid, and
maleic acid.
Representative examples of such diamines include ethylene diamine,
tetramethylene
diamine, hexamethylene diamine, 1,9-nonanediamine, 2-methyl pentamethylene
diamine,
trimethyl hexamethylene diamine (TMD), m-xylylene diamine (MXD), and 1,5-
pentanediamine.
In some embodiments, the polyamide may have been formed by condensation
polymerization of an amino acid (such as 11-aminoundecanoic acid) or ring-
opening
polymerization of a lactam (such as caprolactam or co-aminolauric acid).
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Representative examples of polyamides as may be used in the present disclosure
include: aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12,
polyamide
46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT,
polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T,
polyamide 61,
polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212,
polyamide 12T, polyamide PACM12, polyamide TMDT, polyamide 611, and polyamide
1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, and polyamide
L6T/6I; and aramid polymers.
A polyester is defined as a synthetic linear polymer whose repeating units
contain
ester functional groups, wherein these ester functional groups are integral
members of the
linear polymer chain.
Typical polyesters as used in the present disclosure may be formed by
condensation
of a dicarboxylic acid and a diol. Representative examples of such
dicarboxylic acids
include terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic
acid, 3,4'-
diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-napthalene
dicarboxylic acid,
phthalic acid, 4,4' -methylenebis(benzoic acid), oxalic acid, malonic acid,
succinic acid,
methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic
acid, suberic
acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-
dodecanedicarboxylic
acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic
acid,
tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-
cyclohexanedicarboxylic acid,
1,2-cyclohexanediacetic acid, fumaric acid, and maleic acid. Representative
examples of
such diols include monoethylene glycol, diethylene glycol, triethylene glycol,
poly(ethylene
ether)glycols, 1,3-propanediol, 1,4-butanediol, poly(butylene ether)glycols,
pentamethylene
glycol, 1,6-hexanediol, 1,8- octanediol, 1 ,10-dec anediol, 1 ,12-
dodecanediol, 1,14-
tetradecanediol, 1,16-hexadecanediol, cis-1,4-cyclohexanedimethanol, and trans-
1,4-
cyclohexanedimethanol.
Representative examples of polyesters include poly(ethylene terephthalate)
(PET),
poly(trimethylene terephthalate) (PTT), poly(butylene terephthalate) (PBT),
poly(ethylene
isophthalate), poly(octamethylene terephthalate), poly(decamethylene
terephthalate),
poly(pentamethylene isophthalate), poly(butylene isophthalate),
poly(hexamethylene
isophthalate), poly(hexamethylene adipate),
poly(pentamethylene adipate),
poly(pentamethylene sebacate), poly(hexamethylene sebacate), poly(1,4-
cyclohexylene
terephthalate), poly(1,4-cyclohexylene sebacate), poly(ethylene terephthalate-
co-sebacate),
and poly(ethylene-co-tetramethylene terephthalate).
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A polyolefin comprises a polymer formed from a simple olefin as a monomer.
Representative examples of polyolefins which may be used in the present
disclosure
include, but are not limited to, polyethylene or polypropylene.
In some embodiments, the first polymer comprises polyamide 6 and the second
polymer comprises polyethylene terephthalate. In some embodiments, the first
polymer
comprises polyamide 6 and the second polymer comprises polytrimethylene
terephthalate.
In some embodiments, the first polymer comprises polyamide 6 and the second
polymer
comprises polyethylene. In some embodiments, the first polymer comprises
polyamide 6
and the second polymer comprises polypropylene. In some embodiments, the first
polymer
comprises polyamide 6,6 and the second polymer comprises polyethylene
terephthalate. In
some embodiments, the first polymer comprises polyamide 6,6 and the second
polymer
comprises polytrimethylene terephthalate. In some embodiments, the first
polymer
comprises polyamide 6,6 and the second polymer comprises polyethylene. In some
embodiments, the first polymer comprises polyamide 6,6 and the second polymer
comprises
polypropylene.
In some embodiments, the first polymer comprises polyethylene terephthalate
and
the second polymer comprises polyamide 6. In some embodiments, the first
polymer
comprises polyethylene terephthalate and the second polymer comprises
polyamide 6,6. In
some embodiments, the first polymer comprises polyethylene terephthalate and
the second
polymer comprises polyethylene. In some embodiments, the first polymer
comprises
polyethylene terephthalate and the second polymer comprises polypropylene. In
some
embodiments, the first polymer comprises polytrimethylene terephthalate and
the second
polymer comprises polyamide 6. In some embodiments, the first polymer
comprises
polytrimethylene terephthalate and the second polymer comprises polyamide 6,6.
In some
embodiments, the first polymer comprises polytrimethylene terephthalate and
the second
polymer comprises polyethylene. In some embodiments, the first polymer
comprises
polytrimethylene terephthalate and the second polymer comprises polypropylene.
In some embodiments, the first polymer comprises polyethylene and the second
polymer comprises polyamide 6. In some embodiments, the first polymer
comprises
polyethylene and the second polymer comprises polyamide 6,6. In some
embodiments, the
first polymer comprises polyethylene and the second polymer comprises
polyethylene
terephthalate. In some embodiments, the first polymer comprises polyethylene
and the
second polymer comprises polytrimethylene terephthalate. In some embodiments,
the first
polymer comprises polypropylene and the second polymer comprises polyamide 6.
In some
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embodiments, the first polymer comprises polypropylene and the second polymer
comprises
polyamide 6,6. In some embodiments, the first polymer comprises polypropylene
and the
second polymer comprises polyethylene terephthalate. In some embodiments, the
first
polymer comprises polypropylene and the second polymer comprises
polytrimethylene
terephthalate.
In some embodiments, the first polymer and the second polymer each comprise
polyamide 6. In some embodiments, the first polymer and the second polymer
each
comprise polyamide 6,6. In some embodiments, the first polymer comprises
polyamide 6
and the second polymer comprises polyamide 6,6. In some embodiments, the first
polymer
comprises polyamide 6,6 and the second polymer comprises polyamide 6.
In some embodiments, the first polymer and the second polymer each comprise
polyethylene terephthalate. In some embodiments, the first polymer and the
second polymer
each comprise polytrimethylene terephthalate. In some embodiments, the first
polymer
comprises polyethylene terephthalate and the second polymer comprises
polytrimethylene
terephthalate. In some embodiments, the first polymer comprises
polytrimethylene
terephthalate and the second polymer comprises polyethylene terephthalate.
In some embodiments, the first polymer and the second polymer each comprise
polyethylene. In some embodiments, the first polymer and the second polymer
each
comprise polypropylene. In some embodiments, the first polymer comprises
polyethylene
and the second polymer comprises polypropylene. In some embodiments, the first
polymer
comprises polypropylene and the second polymer comprises polyethylene.
In one aspect, a plurality of solid particles are dispersed within the second
polymer.
In some embodiments, the first component may further comprise a plurality of
solid
particles dispersed in the first polymer, the plurality of solid particles
having a concentration
by volume in the first polymer that is less than a concentration by volume of
the particles of
the second polymer. In some embodiments, the solid particles are evenly
dispersed in the
first polymer. In sonic embodiments, the plurality of solid particles have a
concentration
volume in the first polymer that is 10% less, 20% less, 30% less, 40% less,
50% less, 60%
less, 70% less, 80% less, or 90% less than the concentration by volume of the
particles in
the second polymer. In other embodiments, the first component does not
comprise solid
particles dispersed in the first polymer.
In some embodiments, the solid particles may have an average particle diameter
ranging from 5 microns to 35 microns, for example from 5 micron to 30 microns,
from 5
microns to 25 microns, from 5 microns to 20 microns, from 5 microns to 15
microns, from 5
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microns to 10 microns, from 10 microns to 35 microns, from 10 microns to 30
microns,
from 10 microns to 25 microns, from 10 microns to 20 microns, from 10 microns
to 15
microns, from 15 microns to 35 microns, from 15 microns to 30 microns, from 15
microns
to 25 microns, from 15 microns to 20 microns, from 20 microns to 35 microns,
from 20
microns to 30 microns, from 20 microns to 25 microns, from 25 microns to 35
microns,
from 25 microns to 30 microns, or from 30 microns to 35 microns. In some
embodiments,
the solid particles may have an average particle diameter of 5 microns, 6
microns, 7
microns, 8 microns, 9 microns, 10 microns, 11 microns, 12 microns, 13 microns,
14
microns, 15 microns, 16 microns, 17 microns, 18, microns, 19 microns, 20
microns, 21
microns, 22 microns, 23 microns, 24 microns, 25 microns, 26 microns, 27
microns, 28
microns, 29 microns, 30 microns, 31 microns, 32 microns, 33 microns, 34
microns, or 35
microns.
In some embodiments, the solid particles may comprise glass flakes. In some
embodiments, the glass flakes may comprise E-glass, C-glass, E-CR-glass, or
combinations
thereof. "E-glass" refers to alumino-borosilicate glass having less than 1%
alkali oxides by
weight. "C-glass" refers to alkali-lime glass with a high boron oxide content.
"E-CR-glass"
refers to alumino-lime silicate glass with less than 1% alkali oxides by
weight.
In some embodiments, the glass flakes may have an average particle diameter
ranging from 5 microns to 35 microns, for example from 5 micron to 30 microns,
from 5
microns to 25 microns, from 5 microns to 20 microns, from 5 microns to 15
microns, from 5
microns to 10 microns, from 10 microns to 35 microns, from 10 microns to 30
microns,
from 10 microns to 25 microns, from 10 microns to 20 microns, from 10 microns
to 15
microns, from 15 microns to 35 microns, from 15 microns to 30 microns, from 15
microns
to 25 microns, from 15 microns to 20 microns, from 20 microns to 35 microns,
from 20
microns to 30 microns, from 20 microns to 25 microns, from 25 microns to 35
microns,
from 25 microns to 30 microns, or from 30 microns to 35 microns. In some
embodiments,
the glass flakes have an average particle diameter of 5 microns, 6 microns, 7
microns, 8
microns, 9 microns, 10 microns, 11 microns, 12 microns, 13 microns, 14
microns, 15
microns, 16 microns, 17 microns, 18, microns, 19 microns, 20 microns, 21
microns, 22
microns, 23 microns, 24 microns, 25 microns, 26 microns, 27 microns, 28
microns, 29
microns, 30 microns, 31 microns, 32 microns, 33 microns, 34 microns, or 35
microns. In
some embodiments, the glass flakes may have an average diameter ranging from
27 microns
to 32 microns. In some embodiments, the glass flakes may have an average
diameter
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ranging from 20 microns to 50 microns. In some embodiments, the glass flakes
may have an
average diameter ranging from 8 microns to 12 microns.
In some embodiments, the glass flakes may have an average thickness ranging
from
0.5 microns to 8 microns, for example 0.5 microns to 7 microns, 0.5 microns to
6 microns,
0.5 microns to 5 microns, 0.5 microns to 4 microns, 0.5 microns to 3 microns,
0.5 microns
to 2 microns, 0.5 microns to 1 micron, 1 micron to 8 microns, 1 micron to 7
microns, 1
micron to 6 microns, 1 micron to 5 microns, 1 micron to 4 microns, 1 micron to
3 microns,
1 micron to 2 microns, 2 microns to 8 microns, 2 microns to 7 microns, 2
microns to 6
microns, 2 microns to 5 microns, 2 microns to 4 microns, 2 microns to 3
microns, 3 microns
1() to 8 microns, 3 microns to 7 microns, 3 microns to 6 microns, 3 microns
to 5 microns, 3
microns to 4 microns, 4 microns to 8 microns, 4 microns to 7 microns, 4
microns to 6
microns, 4 microns to 5 microns, 5 microns to 8 microns, 5 microns to 7
microns, 5 microns
to 6 microns, 6 microns to 8 microns, 6 microns to 7 microns, or 7 microns to
8 microns. In
some embodiments, the glass flakes may have an average thickness of 0.5
microns, 0.6
microns, 0.7 microns, 0.8 microns, 0.9 microns, 1 micron, 1.2 microns, 1.4
microns, 1.6
microns, 1.8 microns, 2.0 microns, 2.2 microns, 2.4 microns, 2.6 microns, 2.8
microns, 3.0
microns, 3.2 microns, 3.4 microns, 3.6 microns, 3.8 microns, 4.0 microns, 4.2
microns, 4.4
microns, 4.6 microns, 4.8 microns, 5.0 microns, 5.2 microns, 5.4 microns, 5.6
microns, 5.8
microns, 6.0 microns, 6.2 microns, 6.4 microns, 6.6 microns, 6.8 microns, 7.0
microns, 7.2
microns, 7.4 microns, 7.6 microns, 7.8 microns, or 8.0 microns.
In some embodiments, the glass flakes comprise E-glass flakes having an
average
diameter ranging from 27 microns to 32 microns and an average thickness
ranging from 0.9
microns to 1.3 microns. In some embodiments, the glass flakes comprise E-glass
flakes
having an average diameter ranging from 27 microns to 32 microns and an
average
thickness ranging from 3 microns to 7 microns.
In some embodiments, the glass flakes comprise C-glass flakes having an
average
diameter ranging from 20 microns to 50 microns and an average thickness
ranging from 3
microns to 7 microns.
In some embodiments, the glass flakes comprise E-CR-glass flakes having an
average diameter ranging from 27 microns to 32 microns and an average
thickness ranging
from 0.9 microns to 1.3 microns. In some embodiments, the glass flakes
comprise E-CR-
glass flakes having an average diameter ranging from 8 microns to 12 microns
and an
average thickness ranging from 0.9 microns to 1.3 microns. In some
embodiments, the glass
flakes comprise E-CR-glass flakes having an average diameter ranging from 27
microns to
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32 microns and an average thickness ranging from 2.3 microns to 3.3 microns.
In some
embodiments, the glass flakes comprise E-CR-glass flakes having an average
diameter
ranging from 27 microns to 32 microns and an average thickness ranging from 4
microns to
6 microns.
In some embodiments, the solid particles may comprise mica particles.
Typically, the
mica particles comprise ground mica, for example wet-ground mica which
maintains the
brilliance of the cleavage faces of the sheet material. The mica particles as
used in the
present disclosure may comprise muscovite, paragonite, biotite, lepidolite,
phlogopite,
zinnwaldite, clintonite, hydro-muscovite, illite, phengite, or sericite.
In some embodiments, the solid particles, for example glass flakes or mica
particles,
may be surface treated with a coating prior to being dispersed within the
second polymer.
This coating can reduce the abrasiveness of the solid particles. In some
embodiments, the
coating comprises a silane coating. Representative examples of silane coatings
which may
be used in the present disclosure include, but are not limited to, 3-
aminopropyltriethoxysilane, vinyltrimethoxysilane, 3-
glycidoxypropyltrimethoxysilane, or
3-methacryloxypropyltrimethoxysilane.
In some embodiments, the solid particles, for example glass flakes or mica
particles,
may have a concentration of at least 10% by volume within the second polymer.
In some
embodiments, the solid particles, for example glass flakes, may have a
concentration of
10%, 15%, 20%, 25%, 30%, 35% or 40% by volume within the second polymer.
In some embodiments, the filaments may further comprise one or more additives
including, but limited to: flame retardant additives, for example
decabromodiphenyl ether
and triarylphosphates such as triphenyl phosphate; reinforcing agents; thermal
stabilizers,
for example thermal conductivity improvers such as zinc oxide and titanium
oxide;
ultraviolet light stabilizers such as resorcinol monobenzoates, phenyl
salicylate and 2-
hydroxybenzophenones; hindered amine stabilizers such as benzotriazole,
benzophenone,
oxalanilide, and cerium oxide; impact modifiers; flow enhancing additives;
ionomers; liquid
crystal polymers; fluoropolymers; olefins including cyclic olefins;
polyamides; ethylene
vinyl acetate copolymers; stabilizing agents such as ortho-phosphoric acid,
triphenylphosphate, and triethylphosphino acetate; delustering agents such as
titanium
oxide; carriers such as o-phenylphenol, p-phenylphenol, o-dichlorobenzene,
trichlorobenzene, monochlorobenzene, biphenyl, methyl salicylate, butyl
benzoate, benzyl
benzoate, benzoic acid, benzalacetone, and methyl cinnamate; leveling agents
such as
bishydroxymethyloxazoline, diaryl ethers, ditolyl ether, sodium di-
naphthylmethane-B ,B-
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disulfonate, ammonium dodecylbenzene sulfonate, sodium tetrapropylbenzene
sulfonate,
homopolymers or oligomers of N-vinylpyrrolidone and poly(tetrahydrofuran); and
porosity
additives such as metal oxalate complexes, organic sulfonate salts, jade
powder, and zeolite
powder.
In some embodiments according to any of the first through third aspects, the
multi-
component filament or yarn may have a luster greater than a multi-component
filament or
yarn that comprises the first polymer and the second polymer without the solid
particles.
"Luster" refers to the brightness or sheen of the filament and is associated
with the degree
of light that is reflected from the surface of the filament or the degree of
gloss or sheen that
the filament possesses. The inherent chemical and physical structure and shape
of the fiber
can affect the relative luster of the filament. Synthetic filaments may be
characterized by a
variety of luster classifications, such as bright, semi-bright, semi-dull, and
mid-dull, and the
luster can be influenced by heat setting, dyeing, or finishing of any fibers
formed from the
filaments. Luster results from the way light is reflected from the surface.
The more lustrous
a fiber, the more evenly it reflects incident light.
Luster may be measured by any number of commercially available lustermeters as
would be known to one skilled in the art. With such instruments, luster is
measured as the
contrast and ratio between the specular reflectance and the diffuse
reflectance. The specular
reflectance factor can be expressed as Rs (45 /45 gloss), and the diffuse
reflectance factor
expressed as RD (45900 diffuse reflectance). Reflectance indicates the degree
of diffuse
light at 90 degrees to the filament surface with the incident light at 45
degrees to the
filament surface. The angle between the light source and detector is 45
degrees. Gloss
designates the degree of light measured at 45 degrees to the filament surface
with the
incident light again at 45 degrees to the filament surface. The angle between
the light source
and the detector is 90 degrees. Luster is calculated from the ratio of Gloss
to Reflectance as
follows: Luster=100-(4.5)=(RD/Rs).
Also provided are manufactured products, such as textiles including carpets,
produced using a filament or yarn of any one of the first through third
aspects described
herein.
A number of embodiments of the disclosure have been described. Nevertheless,
it
will be understood that various modifications may be made without departing
from the
spirit and scope of the invention. Accordingly, other embodiments are within
the scope of
the following claims.
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