CA3147147A1 - Eco-friendly polyester fibers and microfiber shed-resistance polyester textiles - Google Patents
Eco-friendly polyester fibers and microfiber shed-resistance polyester textiles Download PDFInfo
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- CA3147147A1 CA3147147A1 CA3147147A CA3147147A CA3147147A1 CA 3147147 A1 CA3147147 A1 CA 3147147A1 CA 3147147 A CA3147147 A CA 3147147A CA 3147147 A CA3147147 A CA 3147147A CA 3147147 A1 CA3147147 A1 CA 3147147A1
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- polyester fiber
- melt
- poly
- spun polyester
- sheath
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- 239000000835 fiber Substances 0.000 title claims abstract description 191
- 229920000728 polyester Polymers 0.000 title claims abstract description 113
- 239000004753 textile Substances 0.000 title claims abstract description 27
- 229920001410 Microfiber Polymers 0.000 title claims description 42
- 239000003658 microfiber Substances 0.000 title claims description 42
- 229920000426 Microplastic Polymers 0.000 claims abstract description 27
- -1 poly(alkylene terephthalate Chemical compound 0.000 claims description 69
- 239000000654 additive Substances 0.000 claims description 30
- 238000000034 method Methods 0.000 claims description 25
- 229920001634 Copolyester Polymers 0.000 claims description 17
- 238000004519 manufacturing process Methods 0.000 claims description 14
- 238000005406 washing Methods 0.000 claims description 14
- 239000011248 coating agent Substances 0.000 claims description 13
- 238000000576 coating method Methods 0.000 claims description 13
- 230000000996 additive effect Effects 0.000 claims description 12
- 238000002074 melt spinning Methods 0.000 claims description 12
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- 239000003607 modifier Substances 0.000 claims description 4
- 230000004580 weight loss Effects 0.000 claims description 4
- 125000002947 alkylene group Chemical group 0.000 claims description 3
- 238000004900 laundering Methods 0.000 abstract description 23
- 239000002245 particle Substances 0.000 abstract description 16
- 238000004140 cleaning Methods 0.000 abstract description 9
- 239000000463 material Substances 0.000 abstract description 6
- 230000003763 resistance to breakage Effects 0.000 abstract description 3
- 150000001991 dicarboxylic acids Chemical class 0.000 description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 229920000139 polyethylene terephthalate Polymers 0.000 description 9
- 239000005020 polyethylene terephthalate Substances 0.000 description 9
- 229920000642 polymer Polymers 0.000 description 9
- 239000000203 mixture Substances 0.000 description 8
- 229920003023 plastic Polymers 0.000 description 8
- 239000004033 plastic Substances 0.000 description 8
- 230000008569 process Effects 0.000 description 8
- 238000012360 testing method Methods 0.000 description 8
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 7
- 150000002009 diols Chemical class 0.000 description 6
- 239000004744 fabric Substances 0.000 description 6
- 238000009472 formulation Methods 0.000 description 6
- 238000004458 analytical method Methods 0.000 description 5
- 230000009467 reduction Effects 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 4
- 238000013459 approach Methods 0.000 description 4
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 239000011159 matrix material Substances 0.000 description 4
- 239000011859 microparticle Substances 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000002671 adjuvant Substances 0.000 description 3
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- 230000001788 irregular Effects 0.000 description 3
- 230000000116 mitigating effect Effects 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 238000010998 test method Methods 0.000 description 3
- 230000007704 transition Effects 0.000 description 3
- DNIAPMSPPWPWGF-VKHMYHEASA-N (+)-propylene glycol Chemical compound C[C@H](O)CO DNIAPMSPPWPWGF-VKHMYHEASA-N 0.000 description 2
- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 description 2
- YPFDHNVEDLHUCE-UHFFFAOYSA-N 1,3-propanediol Substances OCCCO YPFDHNVEDLHUCE-UHFFFAOYSA-N 0.000 description 2
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 230000000845 anti-microbial effect Effects 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- 229920000229 biodegradable polyester Polymers 0.000 description 2
- 239000004622 biodegradable polyester Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000006229 carbon black Substances 0.000 description 2
- 150000007942 carboxylates Chemical class 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 239000002537 cosmetic Substances 0.000 description 2
- 125000001072 heteroaryl group Chemical group 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000002667 nucleating agent Substances 0.000 description 2
- 229920001558 organosilicon polymer Polymers 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 239000004014 plasticizer Substances 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920000166 polytrimethylene carbonate Polymers 0.000 description 2
- 230000006641 stabilisation Effects 0.000 description 2
- 238000011105 stabilization Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 239000002351 wastewater Substances 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- XOJVVFBFDXDTEG-UHFFFAOYSA-N Norphytane Natural products CC(C)CCCC(C)CCCC(C)CCCC(C)C XOJVVFBFDXDTEG-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 239000012963 UV stabilizer Substances 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 230000035508 accumulation Effects 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
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- 239000012765 fibrous filler Substances 0.000 description 1
- 239000000706 filtrate Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 238000009998 heat setting Methods 0.000 description 1
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- 238000005259 measurement Methods 0.000 description 1
- 239000006078 metal deactivator Substances 0.000 description 1
- 239000011325 microbead Substances 0.000 description 1
- 238000000386 microscopy Methods 0.000 description 1
- 239000004005 microsphere Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 229920001277 pectin Polymers 0.000 description 1
- 239000001814 pectin Substances 0.000 description 1
- 235000010987 pectin Nutrition 0.000 description 1
- 229920000768 polyamine Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 229920001282 polysaccharide Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
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- 150000004756 silanes Chemical class 0.000 description 1
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- 239000010457 zeolite Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/08—Melt spinning methods
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
- D01D5/30—Conjugate filaments; Spinnerette packs therefor
- D01D5/34—Core-skin structure; Spinnerette packs therefor
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/10—Other agents for modifying properties
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/78—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products
- D01F6/84—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from copolyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
- D04B1/16—Other fabrics or articles characterised primarily by the use of particular thread materials synthetic threads
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/22—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration
- D04B1/24—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration wearing apparel
- D04B1/26—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration wearing apparel stockings
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
- D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/20—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting articles of particular configuration
- D04B21/207—Wearing apparel or garment blanks
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2501/00—Wearing apparel
- D10B2501/02—Underwear
- D10B2501/021—Hosiery; Panti-hose
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Multicomponent Fibers (AREA)
- Artificial Filaments (AREA)
Abstract
The present application is generally concerned with polyester-based fibers, which exhibit enhanced resistance to breakage and attritional wear. More particularly, the inventive fibers may be especially aimed at textile applications, wherein the inventive fibers may reduce the propensity of the textile materials to produce microplastic and nanoplastic particles during use and during laundering or other cleaning operations, which are a known pollution hazard in the natural environment.
Description
ECO-FRIENDLY POLYESTER FIBERS AND MICROFIBER SHED-RESISTANCE
POLYESTER TEXTILES
RELATED APPLICATIONS
[0001] This application claims the priority benefit under 35 U.S.C. 119(e) of U.S.
Provisional Patent Application Serial No. 62/885,536 entitled "ECO-FRIENDLY
POLYESTER
FIBERS AND MICROFB3ER SHED-RESISTANCE POLYESTER TEXTILES," filed August 12, 2019, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field of the Invention
POLYESTER TEXTILES
RELATED APPLICATIONS
[0001] This application claims the priority benefit under 35 U.S.C. 119(e) of U.S.
Provisional Patent Application Serial No. 62/885,536 entitled "ECO-FRIENDLY
POLYESTER
FIBERS AND MICROFB3ER SHED-RESISTANCE POLYESTER TEXTILES," filed August 12, 2019, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field of the Invention
[0002] The present invention is generally concerned with polyester-based fibers, which exhibit enhanced resistance to breakage and attritional wear. More particularly, the inventive fibers may be especially aimed at textile applications, wherein the inventive fibers may reduce the propensity of the textile materials to produce microplastic and nanoplastic particles during formation, use and during laundering or other cleaning operations, which are a known pollution hazard in the natural environment.
2. Description of the Related Art
2. Description of the Related Art
[0003] The presence of visible plastics waste in the natural environment has been noted for many years, indeed almost since such materials first entered widespread use. While initially a nuisance, such pollution, especially in the marine environment, has grown to be a major concern. Large accumulations of pristine or damaged plastics-based products ("macroplastics"), such as packaging, fishing gear, and apparel, have been observed both in the open ocean and on beaches, often in remote locations far from likely sources of such materials.
[0004] More recently, there has been increasing concern regarding the presence of smaller size plastics pollution, commonly referred to as microplastics (i.e., plastics having a particle size of about 100 nm to about 5 mm) and nanoplastics(i.e., plastics having a particle size of about 100 nm or less), both of which may be generally classified as "microplastics." Despite being largely invisible to the naked eye, many experts have expressed concern that such microplastics pollution could have a range of deleterious effects on the planetary ecosystem and food chains.
[0005] Initially, it was deduced that microplastics pollution was derived from two main sources: (1) primary microplastics and (2) secondary microplastics. Generally, primary microplastics refer to low particle size polymer particles deliberately produced for specific purposes. Potential sources of pollution of this type may include, for example, industrial waste from factories producing low particle size forms of polymers (e.g., in the form of emulsions or suspensions); particles used in cosmetic applications, such as skin exfoliants and dental products;
abrasives preparations used in high-pressure cleaning formulations for the likes of buildings, roadways, and ships; and, more recently, very low particle size polymers used in 3D printing inks and in drug delivery systems. Alternatively, secondary microplastics generally refer to small particles produced by the physical and/or chemical degradation of macroplastics already present in the environment.
abrasives preparations used in high-pressure cleaning formulations for the likes of buildings, roadways, and ships; and, more recently, very low particle size polymers used in 3D printing inks and in drug delivery systems. Alternatively, secondary microplastics generally refer to small particles produced by the physical and/or chemical degradation of macroplastics already present in the environment.
[0006] Within the last decade or so, compelling evidence has been found that a major source of microplastics pollution, especially in the marine, riparian, and littoral environments, is polymeric microfibers. Such microfibers appear to be mainly derived from commercial and domestic laundering, or other cleaning processes, carried out on textiles, in the form of apparel, bedding, soft furnishings, carpets, etc. Thus, a third source of microplastics pollution may include microfibers, which generally refers to small polymer particles derived predominantly from commercial or domestic laundering or cleaning of textiles and other fibrous products. Such pollution can be carried into the marine environment via untreated wastewater;
from waste-water treatment plants, whose filters may be inadequate for trapping such small particles; and via rainwater run-off carrying microfibers deposited, by filtrate compost or whatever means, from the land environment. The microplastics from these sources may be derived from the textiles in any of a number of ways including, for example, loose fibers within the textiles as-made; broken sections of fiber, especially from fiber ends; and abraded particles from fiber surfaces. All such microplastics may be produced by wear of the textiles in use, and by damage inflicted within the textile or on the textile during the laundering/cleaning process itself.
from waste-water treatment plants, whose filters may be inadequate for trapping such small particles; and via rainwater run-off carrying microfibers deposited, by filtrate compost or whatever means, from the land environment. The microplastics from these sources may be derived from the textiles in any of a number of ways including, for example, loose fibers within the textiles as-made; broken sections of fiber, especially from fiber ends; and abraded particles from fiber surfaces. All such microplastics may be produced by wear of the textiles in use, and by damage inflicted within the textile or on the textile during the laundering/cleaning process itself.
[0007] Various studies have been, and are being, carried out to ascertain the extent of the microplastics problem. Of especial interest is information on the proportions of the various types of the microplastics. From currently available data, it is estimated that at least a third of all microplastics pollution is in the form of microfibers. Of these microfibers, it has been shown that polyester-based fibers constitute at least half of the man-made fiber-derived pollution.
[0008] The problem of primary microplastics pollution may be largely tackled by legislation, i.e., by implementing stricter rules for plastics producers, and restricting the use of polymer microparticles in certain consumer products. Indeed, many countries have already banned the use of polymer microbeads in cosmetic preparations.
[0009] In the same way, secondary microplastics may be reduced by the use of legal sanctions on dumping of macroplastics, and/or greater incentives for plastics recycling. This does not, however, solve the problem of microplastics from macroplastics already present in the environment.
[0010] In alternative treatments, some methods for filtering out microplastics from littoral environments have been suggested, such as in U.S. Patent No.
8,944,253.
8,944,253.
[0011] In the case of microfibers, legislation is a less useful weapon, and other approaches of a more technical nature are required.
[0012] Attempts have been made to provide washing machines with filters to capture microfibers, such as shown in WO 2019/045632. However, such filters may rapidly clog up, requiring frequent cleaning or replacement, and there still exists the need to safely dispose of the collected microfibers.
[0013] Another possible approach is to provide a simple device which can be placed in the washing machine alongside the laundry to prevent microfibers being expelled into the wastewater system. One such device is a plastic ball-shaped item capable of capturing and holding microfibers as shown in U.S. D833698 and U.S. Patent Application Publication No.
2019/0126326, while U.S. Patent Application Publication No. 2018/0320306 discloses a bag into which one or more laundry items may be placed, which consists of a material capable of filtering out microfibers. While such devices may be effective to some extent, the collected microfibers need to be removed from these devices and, again, require safe disposal.
2019/0126326, while U.S. Patent Application Publication No. 2018/0320306 discloses a bag into which one or more laundry items may be placed, which consists of a material capable of filtering out microfibers. While such devices may be effective to some extent, the collected microfibers need to be removed from these devices and, again, require safe disposal.
[0014] Rather than attempting to collect microfibers before they can pass into the environment, it would be better to produce fibers which have a lower propensity for producing microfibers in the first place. However, attempting to replace current standard fiber-forming and textile-applicable fibers with an entirely new polymer with such properties is not an economically viable option. Thus, what is required is a means of producing fibers based on currently used polymers that shed a minimal amount of microfibers during use and laundering/cleaning whilst being fully suitable for current coloration, finishing, and fabrication technologies.
[0015] A method of achieving this goal has been suggested by De Falco et al., Carbohydrate Polymers, 198, 175, (2018), in which polyamide fibers are surface grafted with a reactive species containing a pectin group. While their results suggest that this process is effective in reducing microfiber production from such fibers, the approach appears to be restricted to polyamides, and involves a number of chemical and physical processes in addition to the basic melt-spinning of the fiber.
[0016] Accordingly, there is still a need for the production of fibers that may help mitigate microplastics pollution.
SUMMARY
SUMMARY
[0017] One or more embodiments of the present invention are generally concerned with a melt-spun polyester fiber for reducing microplastics pollution. Generally, the melt-spun polyester fiber is in the form of: (i) a first core-sheath bicomponent polyester fiber comprising a first core domain and a first sheath domain, wherein the first core domain comprises a fiber-forming poly(alkylene terephthalate) and the first sheath domain comprises a homopolyester or copolyester that is different from the fiber-forming poly(alkylene terephthalate); (ii) a second core-sheath bicomponent polyester fiber comprising a second core domain and a second sheath domain, wherein the second core domain comprises a fiber-forming poly(alkylene terephthalate) and the second sheath domain comprises a homopolyester or copolyester and at least one shed-resistance additive; or (iii) a monocomponent polyester fiber comprising a fiber-forming poly(alkylene terephthalate), wherein the monocomponent polyester fiber is at least partially coated with a shed-resistance coating.
[0018] One or more embodiments of the present invention are generally concerned with a melt-spun polyester fiber for reducing microplastics pollution. Generally, the melt-spun polyester fiber is in the form of: (i) a core-sheath bicomponent polyester fiber comprising a core domain and a sheath domain, wherein the core domain comprises a poly(alkylene terephthalate) and said sheath domain comprises a homopolyester or copolyester and at least one shed-resistance additive; or (ii) a monocomponent polyester fiber comprising a poly(alkylene terephthalate), wherein the monocomponent polyester fiber is at least partially coated with a shed-resistance coating.
[0019] One or more embodiments of the present invention are generally concerned with a melt-spun polyester fiber for reducing microplastics pollution. Generally, the melt-spun polyester fiber is in the form of: (i) a first core-sheath bicomponent polyester fiber comprising a first core domain and a first sheath domain, wherein the first core domain comprises a fiber-forming poly(alkylene terephthalate) and the first sheath domain comprises a homopolyester or copolyester that is different from the fiber-forming poly(alkylene terephthalate); (ii) a second core-sheath bicomponent polyester fiber comprising a second core domain and a second sheath domain, wherein the second core domain comprises a fiber-forming poly(alkylene terephthalate) and the second sheath domain comprises a homopolyester or copolyester and at least one shed-resistance additive; or (iii) a monocomponent polyester fiber comprising a fiber-forming poly(alkylene terephthalate), wherein the monocomponent polyester fiber is at least partially coated with a shed-resistance coating. Furthermore, the melt-spun polyester fiber exhibits a fiber weight loss after a washing cycle of less than 2 weight percent and a waste microfibers loss per gram of tested sample after a washing cycle of less than 10 mg of waste microfibersµ
[0020] One or more embodiments of the present invention are generally concerned with a method for producing the melt-spun polyester fibers described herein.
Generally, the methods involve melt spinning a poly(alkylene terephthalate) to thereby form the melt-spun polyester fiber.
DETAILED DESCRIPTION
Generally, the methods involve melt spinning a poly(alkylene terephthalate) to thereby form the melt-spun polyester fiber.
DETAILED DESCRIPTION
[0021] In order to provide an approach that reduces microfiber production from fibers and textiles by the greatest possible amount, and in an economically viable manner, a melt-extrusion process has been devised for the production of polyester fibers, which may provide fibers and textiles that have a significantly reduced propensity for producing microfibers during use and laundering/cleaning.
[0022] More particularly, the present invention is generally concerned with producing polyester fibers exhibiting a reduced propensity for breakage and attritional wear, which may be primarily produced using standard fiber-forming polyester. This may be achieved through the use of melt-spinning techniques and/or downstream physicochemical treatments.
[0023] As discussed below in greater detail, the inventive fibers described herein may take the form of a variety of embodiments. It should be noted that all of the following properties and ranges concerning the inventive fibers are not mutually exclusive (unless otherwise noted) and, therefore, may be combined in any manner by one skilled in the art as so desired. For example, any one of the thickness ranges could be combined with any one of the weight percentage ranges.
[0024] In one or more embodiments, the inventive fibers can be in the form of core-sheath fibers comprising different polyesters as the sheath domain and core domain.
Additionally or alternatively, in various embodiments, the inventive fibers may be in the form of a core-sheath bicomponent melt-spun fiber, wherein the sheath comprises the same or a different polyester as the core and the sheath contains certain additives and/or a coating that aid reduction in microfiber loss from the inventive fiber.
Additionally or alternatively, in various embodiments, the inventive fibers may be in the form of a core-sheath bicomponent melt-spun fiber, wherein the sheath comprises the same or a different polyester as the core and the sheath contains certain additives and/or a coating that aid reduction in microfiber loss from the inventive fiber.
[0025] Additionally or alternatively, in various embodiments, a coating/spin-finish may be applied on a melt-spun polyester monocomponent fiber or the sheath domain of a core-sheath bicomponent melt-spun fiber, wherein the coating/spin-finish places special additives onto the monocomponent fiber or the sheath domain, which may aid in the reduction in microfiber loss.
[0026] As noted above, in certain embodiments, one method of mitigating microfiber pollution involves melt-spinning a core-sheath bicomponent fiber having a standard fiber-forming polyester as a core domain and a sheath domain of an alternative polyester. The polyester of the sheath domain may be selected from polyesters that: (i) adhere well to the standard fiber-forming polyester of the core domain, (ii) have physical properties that reduce breakage of the core-sheath bicomponent fiber, and/or (iii) are less susceptible to attritional damage compared to the standard fiber-forming polyester of the core domain.
[0027] As noted above, in certain embodiments, another method of mitigating microfiber pollution involves melt-spinning a core-sheath bicomponent fiber having a standard fiber-forming polyester core domain and a sheath domain of the same polyester or a different polyester. In such embodiments, the sheath domain may contain one or more additives and/or a coating that act in such a manner as to provide fibers with a reduced propensity for breakage and/or attritional damage when exposed to laundering processes, especially when compared to fibers made entirely from the polyester of the core domain.
[0028] As noted above, in certain embodiments, yet another method of mitigating microfiber pollution involves melt-spinning a standard fiber-forming polyester into a monocomponent fiber and downstream treating the fiber with a lubricant or other coating formulation, wherein the lubricant or coating formulation contains one or more additives that, when coated onto or impregnated into the polyester fiber, act in such a manner as to provide polyester fibers with reduced propensity for breakage and/or attritional damage when exposed to laundering processes.
[0029] All of the above-referenced embodiments are described in greater detail below. It should be noted that, while some of the following characteristics and properties of the fibers may be listed separately, it is envisioned that each of the following characteristics and/or properties of the fibers are not mutually exclusive and may be combined and present in any combination as long as they do not conflict.
[0030] In various embodiments, the shed-resistant fibers of the present invention can comprise core-sheath bicomponent fibers that exhibit a reduced propensity for breakage and/or attritional wear, thereby significantly reducing the amount of microfiber pollution generated from the fibers and textiles made therefrom. In such embodiments, the core-sheath fibers can be produced from any melt spinning process known in the art Generally, a core-sheath fiber is formed by a core domain being partially or, in most cases, fully encompassed by the sheath domain.
[0031] In certain embodiments, the core-sheath fibers may comprise a core domain at least partially formed by a fiber-forming polyester and a sheath domain at least partially formed by a different polyester. In alternative embodiments, the core-sheath fibers may comprise a core domain at least partially formed by a fiber-forming polyester and a sheath domain at least partially formed by the same polyester.
[0032] The core-sheath bicomponent fibers may be of any suitable overall cross-sectional shape, including, but not limited to, round, square, triangular, flattened, regular multilobal, and irregular multilobal.
[0033] The core domain of the core-sheath bicomponent fibers may be of any suitable cross-sectional shape, the shape being the same as or different from the overall cross-sectional shape of the core-sheath fibers, including, but not limited to, round, square, triangular, flattened, regular multilobal, and irregular multilobal.
[0034] The sheath domain of the core-sheath bicomponent fibers may cover the entire perimeter of the core domain of the fibers. Additionally, in various embodiments, the thickness of the sheath domain may constitute 50% or less, 40% or less, 30% or less, 20%
or less, 10% or less, or 5% or less of the average radius of the core-sheath fibers.
Additionally or alternatively, in various embodiments, the core-sheath bicomponent fibers may comprise at least 1, 2, 5, 10, or 15 percent by volume and/or less than 50, 45, 40, 35, 30, 25, 20, 15, or 10 percent by volume of the sheath domain based on the total volume of the bicomponent fibers.
Furthermore, in various embodiments, the core-sheath bicomponent fibers may comprise at least 10, 15, 20, 25, 30, 35, 40, 45, or 50 percent by volume and/or less than 95, 90, 85, 80, 75, 70, 65, 60, or 55 percent by volume of the core domain based on the total volume of the bicomponent fibers.
or less, 10% or less, or 5% or less of the average radius of the core-sheath fibers.
Additionally or alternatively, in various embodiments, the core-sheath bicomponent fibers may comprise at least 1, 2, 5, 10, or 15 percent by volume and/or less than 50, 45, 40, 35, 30, 25, 20, 15, or 10 percent by volume of the sheath domain based on the total volume of the bicomponent fibers.
Furthermore, in various embodiments, the core-sheath bicomponent fibers may comprise at least 10, 15, 20, 25, 30, 35, 40, 45, or 50 percent by volume and/or less than 95, 90, 85, 80, 75, 70, 65, 60, or 55 percent by volume of the core domain based on the total volume of the bicomponent fibers.
[0035] Furthermore, in various embodiments, the interface between the core domain and the sheath domain of the core-sheath bicomponent fibers may be smooth, may comprise of regular multiple peaks and troughs, or may comprise of irregular multiple peaks and troughs.
[0036] In one or more embodiments, the core domain of the core-sheath bicomponent fiber may be at least partially formed or entirely formed from a fiber-forming poly(alkylene terephthalate) polyester. In such embodiments, the alkylene moiety may be derived from a C2-io aliphatic diol or a derivative thereof, and is preferably selected from 1,2-ethanediol, 1,3-propanediol, and 1,4-butanediol. In certain embodiments, the core domain of the core-sheath bicomponent fiber may be at least partially formed or entirely formed from poly(1,2-ethylene terephthalate), poly(1,3-propylene terephthalate), poly(1,4-butylene terephthalate), or combinations thereof. In particular embodiments, the core domain of the core-sheath bicomponent fiber may be at least partially formed or entirely formed from poly(1,2-ethylene terephthalate). In even more particular embodiments, the core domain of the core-sheath bicomponent fiber may be at least partially formed or entirely formed from a non-biodegradable polyester.
[0037] In one or more embodiments, the core domain of the core-sheath bicomponent fiber may comprise at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 weight percent of at least one poly(alkylene terephthalate) polyester.
[0038] Additionally or alternatively, in one or more embodiments, the sheath domain of the core-sheath bicomponent fiber may be at least partially formed or entirely formed from a fiber-forming poly(alkylene terephthalate) polyester. In such embodiments, the alkylene moiety may be derived from a C2-10 aliphatic diol or a derivative thereof, and is preferably selected from 1,2-ethanediol, 1,3-propanediol, and 1,4-butanediol. In certain embodiments, the sheath domain of the core-sheath bicomponent fiber may be at least partially formed or entirely formed from poly(1,2-ethylene terephthal ate), poly(1,3-propylene terephthalate), poly(1,4-butylene terephthalate), or combinations thereof. In particular embodiments, the core domain of the core-sheath bicomponent fiber may be at least partially formed or entirely formed from poly(1,4-butylene terephthalate). In particular embodiments, the sheath domain of the core-sheath bicomponent fiber may be at least partially formed or entirely formed from a non-biodegradable polyester.
[0039] Additionally or alternatively, in one or more embodiments, the sheath domain of the core-sheath bicomponent fiber may comprise at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 weight percent of at least one poly(alkylene terephthalate) polyester.
[0040] In one or more embodiments, the sheath domain of the core-sheath bicomponent fibers may comprise a homopolyester, wherein the homopolyester is different from or the same as the polyester forming the core domain of the fiber. In such embodiments, the homopolyester may comprise a poly(alkylene carboxylate), a poly(cycloalkylene carboxylate), a poly(arylene carboxylate), a poly(aralkylene carboxylate), or combinations thereof The carboxylate moiety in any of the homopolyesters may be derived from an aromatic dicarboxylic acid, an araliphatic dicarboxylic acid, an aliphatic dicarboxylic acid, a cycloaliphatic dicarboxylic acid, a hetroaromatic dicarboxylic acid, a heteroaliphatic dicarboxylic acid, a heterocycloaliphatic dicarboxylic acid, or derivatives thereof.
[0041] In one or more embodiments, the sheath domain of the core-sheath bicomponent fibers may comprise a copolyester, wherein the copolyester contains moieties derived from diols or derivatives thereof and moieties derived from dicarboxylic acids or derivatives thereof.
[0042] The diols used to produce the polyesters may comprise, for example, straight chain aliphatic diols, branched aliphatic diols, unsubstituted cycloaliphatic diols, substituted cycloaliphatic diols, unsubstituted aromatic dials, substituted aromatic diols, unsubstituted araliphatic diols, substituted araliphatic dials, straight chain heteroaliphatic dials, branched heteroaliphatic dials, unsubstituted heterocycloaliphatic dials, substituted heterocycloaliphatic dials, unsubstituted heteroaromatic dials, substituted heteroaromatic dials, unsubstituted heteroaraliphatic dials, substituted heteroaraliphatic dials, or combinations thereof.
[0043] The dicarboxylic acids used to produce the polyesters may comprise, for example, straight chain aliphatic dicarboxylic acids, branched aliphatic dicarboxylic acids, unsubstituted cycloaliphatic dicarboxylic acids, substituted dicarboxylic acids, unsubstituted aromatic dicarboxylic acids, substituted dicarboxylic acids, unsubstituted araliphatic dicarboxylic acids, substituted araliphatic dicarboxylic acids, straight chain heteroaliphatic dicarboxylic acids, branched heteroaliphatic dicarboxylic acids, unsubstituted heterocycloaliphatic dicarboxylic acids, substituted heterocycloaliphatic dicarboxylic acids, unsubstituted heteroaromatic dicarboxylic acids, substituted heteroaromatic dicarboxylic acids, unsusbstituted heteroaraliphatic dicarboxylic acids, substituted heteoaraliphatic dicarboxylic acids, or combinations thereof.
[0044] In one or more embodiments, the sheath domain may comprise at least two layers, including an inner layer and an outer layer. The inner layer may be at least partially formed or entirely formed from a homopolyester or copolyester that exhibits a compatibilization or adhesion function, while the outer layer may be at least partially formed or entirely formed from a homopolyester or copolyester that provides the desired resistance to breakage and/or attritional damage. In such embodiments, the homopolyester or copolyester of the inner layer may be different from that of the outer layer. Furthermore, the inner layer and the outer layer may be formed from the homopolyesters and copolyesters hereinbefore described. In certain embodiments, the inner layer may completely encompass and cover the core domain and the outer layer may at least partially encompass or entirely encompass the inner layer.
[0045] In one or more embodiments, the polyesters and/or the dials and diacids used in the preparation of the polyesters may be derived from one or more of petrochemical resources, renewable resources, and/or recycled resources.
[0046] Alternatively, in various embodiments, the shed-resistant fibers of the present invention can comprise monocomponent fibers that exhibit a reduced propensity for breakage and/or attritional wear, thereby significantly reducing the amount of microfiber pollution generated from the fibers and textiles made therefrom.
In such embodiments, the monocomponent fibers can be produced from any melt spinning process known in the art. It should be noted that the monocomponent fibers may be produced by the homopolyesters and copolyesters hereinbefore described.
In such embodiments, the monocomponent fibers can be produced from any melt spinning process known in the art. It should be noted that the monocomponent fibers may be produced by the homopolyesters and copolyesters hereinbefore described.
[0047] In one or more embodiments, the sheath domain of the core-sheath fibers or the monocomponent fibers may comprise one or more shed-resistance additives, which may alter the physical properties of the sheath domain polyester or of the polyester forming the monocomponent fiber in such a way so as to form fibers with a reduced propensity towards breakage and/or attritional damage. Consequently, this can result in the production of fibers, yarns, and textiles that may shed significantly lower amounts of microfibers during use and laundering. In the case of the core-sheath fibers containing a sheath domain with multiple layers, the shed-resistance additives may be present in all the layers or separate distinct layers (e.g., the additives may be present in the outer layer, but absent in the inner layer).
Exemplary shed-resistance additives can include, for example, lubricants, impact modifiers, crosslinkers and chain extenders, crystallization modifiers, low molecular weight substances such as oligomers or polymers, or combinations thereof In certain embodiments, the fibers of the present invention may comprise at least 0.1, 0.5, 1, 2, 3, 4, or 5 and/or not more than 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of at least one shed-resistance additive.
Exemplary shed-resistance additives can include, for example, lubricants, impact modifiers, crosslinkers and chain extenders, crystallization modifiers, low molecular weight substances such as oligomers or polymers, or combinations thereof In certain embodiments, the fibers of the present invention may comprise at least 0.1, 0.5, 1, 2, 3, 4, or 5 and/or not more than 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of at least one shed-resistance additive.
[0048] Lubricants may include, but are not limited to, one or more of hydrocarbons, fluorocarbons, or silicones, such as organosilicon polymers.
[0049] Impact modifiers may include, but are not limited to, one or more of rubbers, addition copolymers, condensation copolymers, microspheres, or fibers.
[0050] Crosslinkers and chain extenders may include, but are not limited to, one or more of polyols, polyamines, polyacids, or silanes.
[0051] Crystallization modifiers may include, but are not limited to, one or more crystallization nucleating agents and/or one or more crystallization suppression agents.
[0052] In one or more embodiments, the sheath domain of the core-sheath fibers or the monocomponent fibers may comprise a shed-resistance coating or lubricant. In such embodiments, the core-sheath fibers or the monocomponent fibers may be surfaced treated or subjected to a lubricant in a continuous or discontinuous manner after melt spinning. The coating formulation or lubricant may contain one or more additives which, when coated onto, or impregnated into, the outer region of the fibers, provides the fibers with a reduced propensity towards breakage and/or attritional damage. Consequently, this can result in the production of fibers, yarns, and textiles that may shed significantly lower amounts of microfibers during use and laundering. In certain embodiments, the fibers of the present invention may comprise at least 0.1, 0.5, 1, 2, 3, 4, or 5 and/or not more than 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of at least one shed-resistance coating or lubricant. It should be noted that the shed-resistance coating or shed-resistance lubricant may comprise one or more of the above-referenced shed-resistance additives.
[0053] In one or more embodiments, the polyesters forming the core domain, the sheath domain, and/or the monocomponent fibers may optionally comprise active formulation additives.
Such active formulation additives may include, but are not limited to, colorants, UV stabilizers, antioxidants, metal deactivators, nucleating agents, fire retardants, particulate or fibrous fillers, antimicrobials, antistatics, processing aids, and combinations thereof. In certain embodiments, the fibers of the present invention may comprise at least 0.1, 0.5, 1, 2, 3, 4, or 5 and/or not more than 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of at least one active formulation additive.
Such active formulation additives may include, but are not limited to, colorants, UV stabilizers, antioxidants, metal deactivators, nucleating agents, fire retardants, particulate or fibrous fillers, antimicrobials, antistatics, processing aids, and combinations thereof. In certain embodiments, the fibers of the present invention may comprise at least 0.1, 0.5, 1, 2, 3, 4, or 5 and/or not more than 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of at least one active formulation additive.
[0054] In one or more embodiments, the polyesters forming the core domain, the sheath domain, and/or the monocomponent fibers may not contain any plasticizers, carbon black, and/or antimicrobial additives, such as zeolites or metal-based antimicrobial agents (e.g., metal-based antimicrobial agents, such as silver-based agents). For instance, the core domain and/or the sheath domain of the core-sheath fibers or the monocomponent fibers may comprise less than 1, 0.5, 0.1, 0.05, 0.01, 0.005, or 0.001 weight percent of plasticizers, carbon black., and/or antimicrobial additives.
[0055] In one or more embodiments, the bicomponent fibers and/or the monocomponent fibers may comprise a deniers per filament ("dpf') of at least 0.1, 0.5, 1, 2, or 3 and/or not more than 20, 15, 10,9, 8, 7, 6, 5, or 4 dpi
[0056] As noted above, the core-sheath fibers and the monocomponent fibers of the present invention may be melt-spun using equipment and methods known to those skilled in the art. Exemplary melt spinning equipment and techniques are described in U.S.
Patent No.
5,162,074 and U.S. Patent No. 6,783,854, the disclosures of which are incorporated herein by reference in their entireties.
Patent No.
5,162,074 and U.S. Patent No. 6,783,854, the disclosures of which are incorporated herein by reference in their entireties.
[0057] The core-sheath fibers and the monocomponent fibers of the present invention may be produced in any suitable form, including, but limited to, multifilament yams, staple fiber and yarns, monofilaments, thermoplastic composites, and non-wovens. The fibers or yams melt-spun in this manner may be subjected to known downstream processing methods, including, but not limited to, hot or cold drawing, texturing, heat-setting, cutting, fusing, and/or ban formation.
[0058] Due to the unique shed-resistance properties, the fibers of the present invention may exhibit a fiber weight loss after a washing cycle of less than 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 03, 0.2, 0.1, 0.05, or 0.01 weight percent. The washing cycle for this test can be carried out at 40 C for 30 minutes at 1,400 rpm and in the absence of a detergent. The fibers or sample textile can be dried after the washing cycle at 80 C for 24 hours. The mass of the resulting fiber mass or sample textile can then be measured and compared against the initial mass of the fibers or sampled textile to calculate the percent fiber loss.
[0059] Additionally, due to the unique shed-resistance properties, the fibers of the present invention may exhibit a waste microfibers loss per gram of tested sample after the above-referenced washing cycle of less than 100, 75, 50, 40, 30, 20, 15, 10, 5, 1, 0.5, 0.1, 0.05, or 0.01 mg of waste microfibers. As used herein, "waste microfibers" refer to fibers derived from the tested sample during the washing cycle and that have an average length of less than 5 mm and an average diameter of less than 50 microns.
[0060] Furthermore, due to the unique shed-resistance properties, the fibers of the present invention may exhibit a percent reduction in microparticle area of at least 10, 15, 20, 25, 30, 35, 40, or 45 percent and/or not more than 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, or 30 percent, as calculated with ImageJ software after laundering in accordance with test method AATCC TM 61 and based on laundering regime 2A or 3A. In regime 2A, the wash canister contains 150 ml of wash water and 50 steel balls, and the temperature is set at 49 2 C. In regime 3A, the wash canister contains 50 ml of wash water and 100 steel balls, with the temperature set at 71 2 C.
In both regimes, the wash water also contains 0.15% detergent and the wash-cycle time is 45 minutes.
In both regimes, the wash water also contains 0.15% detergent and the wash-cycle time is 45 minutes.
[0061] The fibers or yarns of the present invention may be used in the manufacture of various woven, knitted, tufted, webbed, and/or non-woven textiles or in the manufacture of woven, knitted, non-woven, and/or tufted floorcoverings. The textiles produced from the fibers or yarns of the present invention may also be used in the manufacture of finished goods, including, but not limited to, apparel, towels, soft furnishings, and bedding.
[0062] Moreover, as the core-sheath bicomponent fibers and the monocomponent fibers of the present invention are made entirely of polyesters derived from dicarboxylic acids and diols, the fibers or articles made therefrom can, at the end of their useful life, be chemically recycled to starting materials using methods known to those skilled in the art.
[0063] This invention can be further illustrated by the following examples of embodiments thereof, although it will be understood that these examples are included merely for the purposes of illustration and are not intended to limit the scope of the invention unless otherwise specifically indicated EXAMPLES
Examples 1-5 and Comparative Example 6
Examples 1-5 and Comparative Example 6
[0064] Multifilament yarns of 100 denier and comprising 36 filaments per yarn and a final draw ratio of about 2.8 were melt spun using equipment and processes familiar to those skilled in the art. The inventive yarns of Examples 1-5 comprised filaments of a core-sheath bicomponent configuration, wherein the core domain constituted 85 percent by volume of the overall filament and the sheath domain constituted 15 percent by volume of the overall filament.
Furthermore, the core domains of Examples 1-5 were formed from poly(ethylene terephthalate) ("PET") and the sheath domain were formed from a thermoplastic polyester optionally containing a shed-resistant additive package comprising polymeric and/or non-polymeric constituents. The formulations of the sheath domains in Examples 1-5 are provided below in TABLE 1.
Example Sheath Formulation 1 PET containing an additive package of organosilicon polymers for softening and/or smoothing of the matrix polyester PET containing an additive package of active adjuvants for thermal and thermo-oxidative stabilization of the matrix polyester 3 PET containing an additive package consisting of active adjuvants for hydrolytic stabilization and intrinsic viscosity enhancement of matrix polyester 4 PET containing an additive package of active adjuvants for crystallization control of the matrix polyester Poly(butylene terephthalate)
Furthermore, the core domains of Examples 1-5 were formed from poly(ethylene terephthalate) ("PET") and the sheath domain were formed from a thermoplastic polyester optionally containing a shed-resistant additive package comprising polymeric and/or non-polymeric constituents. The formulations of the sheath domains in Examples 1-5 are provided below in TABLE 1.
Example Sheath Formulation 1 PET containing an additive package of organosilicon polymers for softening and/or smoothing of the matrix polyester PET containing an additive package of active adjuvants for thermal and thermo-oxidative stabilization of the matrix polyester 3 PET containing an additive package consisting of active adjuvants for hydrolytic stabilization and intrinsic viscosity enhancement of matrix polyester 4 PET containing an additive package of active adjuvants for crystallization control of the matrix polyester Poly(butylene terephthalate)
[0065] For Comparative Example 6, a yarn consisting of poly(ethylene terephthalate) monofilaments of the same overall denier and fiber count was melt-spun under the same conditions as used for the manufacture of Examples 1-5.
[0066] The inventive yams noted in TABLE 1, along with the comparative poly(ethylene terephthalate) yarn, were each single thread-line jersey knitted into socks.
Two distinctive analytical methods were used to describe the rate of microfiber shed: (i) analysis of deposited microfiber shed on filtration media and (ii) particle analysis of shed microfibers using Imagek
Two distinctive analytical methods were used to describe the rate of microfiber shed: (i) analysis of deposited microfiber shed on filtration media and (ii) particle analysis of shed microfibers using Imagek
[0067] For testing the accelerated wear and collected microfiber shed, samples measuring 3.5 inches by 5 inches were cut from the socks, and the edges thereof heat-sealed and trimmed to remove rough edges.
[0068] The aforementioned samples were then subjected to simulated wear using a model CM1 Crockmeter (Atlas Electric Devices). Fabric samples were attached to the stationary bottom portion of the Crockmeter, while a stainless-steel screen with 25 mm pore size was attached to the oscillating upper portion. The stainless-steel screen was oscillated against each fabric surface 30 times to generate wear on the samples.
[0069] Visual examination of the tested samples noted that all inventive samples exhibited less wear than the comparative sample when passed through a multi-stage filter of 200 x 200 gm, 100 x 100 gm, 25 x 25 pm, and 450 nm, in series. A quantitative measurement, using the same abrasion and laundering procedure of the replicate samples described above with the Crockmeter, was collected using a single 10 x 10 micrometer filter. More particularly, after the laundering procedure with the Crockmeter, the samples were placed in 1 liter Laundr-O-meter canisters and tested using optimized conditions to generate wear on the samples (2 hours, 45 C, 50 stainless steel balls, 200 g DI water). The fabric was then allowed to dry.
The resulting laundry water was also filtered using an approximate 10 pm filter to compare lint generation between samples (sample mass). The collected material was weighed, and the results are given in TABLE 2, below.
Example Percent Reduction in Microparticle Mass Generated in Laundering
The resulting laundry water was also filtered using an approximate 10 pm filter to compare lint generation between samples (sample mass). The collected material was weighed, and the results are given in TABLE 2, below.
Example Percent Reduction in Microparticle Mass Generated in Laundering
[0070] For particle analysis in laundering water, testing of samples was carried out using a standard test apparatus, in the form of an SDL Atlas Laundr-O-Meter M228 Rotowash_ The test protocols used were those described in the test method AATCC TM 61 "Test method for colorfastness in laundering," which is incorporated herein by reference in its entirety.
[0071] Two laundering regimes were used in the tests in an attempt to simulate both standard and harsher washing cycles likely to be encountered during domestic or commercial laundering. The two regimes were referred to as "2A" and "3A." In regime 2A, the wash canister contained 150 ml of wash water and 50 steel balls, and the temperature was set at 49 2 C. In regime 3A, the wash canister contained 50 ml of wash water and 100 steel balls, with the temperature set at 71 2 C. In both regimes, the wash water also contained 0.15% detergent and the wash-cycle time was 45 minutes.
[0072] Samples of the test fabrics and samples of the control fabrics were subjected to both laundering regimes in the device canisters, along with a canister containing no sample as a blank. Following laundering, water samples were extracted from the wash canisters and prepared for imaging using microscopy.
[0073] Results of the laundering tests are provided below in TABLE 3 as a percentage reduction in microparticle area as calculated in 'maga using the particle analysis tools of the ImageJ software, with respect to the control poly(ethylene terephthalate) fabric.
Example Regime 2A
Regime 3A
DEFINITIONS
Example Regime 2A
Regime 3A
DEFINITIONS
[0074] It should be understood that the following is not intended to be an exclusive list of defined terms. Other definitions may be provided in the foregoing description, such as, for example, when accompanying the use of a defined term in context.
[0075] As used herein, the terms "a," "an," and "the" mean one or more.
[0076] As used herein, the term "and/or," when used in a list of two or more items, means that any one of the listed items can be employed by itself or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B
alone; C alone;
A and B in combination; A and C in combination, B and C in combination; or A, B, and C in combination.
alone; C alone;
A and B in combination; A and C in combination, B and C in combination; or A, B, and C in combination.
[0077] As used herein, the terms "comprising," "comprises," and "comprise" are open-ended transition terms used to transition from a subject recited before the term to one or more elements recited after the term, where the element or elements listed after the transition term are not necessarily the only elements that make up the subject
[0078] As used herein, the terms "having," "has," and "have" have the same open-ended meaning as "comprising," "comprises," and "comprise" provided above.
[0079] As used herein, the terms "including," "include," and "included" have the same open-ended meaning as "comprising," "comprises," and "comprise" provided above.
NUMERICAL RANGES
NUMERICAL RANGES
[0080] The present description uses numerical ranges to quantify certain parameters relating to the invention. It should be understood that when numerical ranges are provided, such ranges are to be construed as providing literal support for claim limitations that only recite the lower value of the range as well as claim limitations that only recite the upper value of the range.
For example, a disclosed numerical range of 10 to 100 provides literal support for a claim reciting "greater than 10" (with no upper bounds) and a claim reciting "less than 100" (with no lower bounds).
CLAIMS NOT LIMITED TO DISCLOSED EMBODIMENTS
For example, a disclosed numerical range of 10 to 100 provides literal support for a claim reciting "greater than 10" (with no upper bounds) and a claim reciting "less than 100" (with no lower bounds).
CLAIMS NOT LIMITED TO DISCLOSED EMBODIMENTS
[0081] The preferred forms of the invention described above are to be used as illustration only and should not be used in a limiting sense to interpret the scope of the present invention.
Modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.
Modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.
[0082] The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as it pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.
Claims (20)
1. A melt-spun polyester fiber for reducing microplastics pollution, wherein said melt-spun polyester fiber is in the form of:
(i) a core-sheath bicomponent polyester fiber comprising a core domain and a sheath domain, wherein said core domain comprises a poly(alkylene terephthalate) and said sheath domain comprises a homopolyester or copolyester and at least one shed-resistance additive; or (ii) a monocomponent polyester fiber comprising a poly(alkylene terephthalate), wherein said monocomponent polyester fiber is at least partially coated with a shed-resistance coating.
(i) a core-sheath bicomponent polyester fiber comprising a core domain and a sheath domain, wherein said core domain comprises a poly(alkylene terephthalate) and said sheath domain comprises a homopolyester or copolyester and at least one shed-resistance additive; or (ii) a monocomponent polyester fiber comprising a poly(alkylene terephthalate), wherein said monocomponent polyester fiber is at least partially coated with a shed-resistance coating.
2. The melt-spun polyester fiber according to claim 1, wherein said poly(alkylene terephthalate) comprises poly(1,2-ethylene terephthalate), poly(1,3-propylene terephthalate), or poly(1,4-butylene terephthalate), and wherein said homopolyester or said copolyester comprises poly(1,2-ethylene terephthalate), poly(1,3 -propylene terephthalate), or poly(1,4-butylene terephthalate).
3. The melt-spun polyester fiber according to claim 2, wherein said melt-spun polyester fiber is said core-sheath bicomponent polyester fiber.
4. The melt-spun polyester fiber according to claim 3, wherein said sheath domain comprises an inner layer and an outer layer.
5. The melt-spun polyester fiber according to claim 4, wherein said inner layer and said outer layer are formed from different polyesters.
6. The melt-spun polyester fiber according to claim 3, wherein said melt-spun polyester fiber comprises 0.1 to 25 weight percent of said shed-resistance additives.
7. The melt-spun polyester fiber according to claim 6, wherein said shed-resistance additives comprise a lubricant, an impact modifier, a crosslinker, a chain extender, a crystallization modifier, or combinations thereof.
8. The melt-spun polyester fiber according to claim 1, wherein said melt-spun polyester fiber is said monocomponent polyester fiber.
9 The melt-spun polyester fiber according to claim 8, wherein said melt-spun polyester fiber comprises 0 1 to 25 weight percent of said shed-resistance coating, wherein said shed-resistance coafing comprises one or more shed-resistance additives.
10. The melt-spun polyester fiber according to claim 9, wherein said shed-resistance additives comprise a lubricant, an impact modifier, a crosslinker, a chain extender, a crystallization modifier, or combinations thereof.
11. The melt-spun polyester fiber according to claim 1, wherein said melt-spun polyester fiber exhibits a fiber weight loss after a washing cycle of less than 2 weight percent.
12. The melt-spun polyester fiber according to claim 1, wherein said melt-spun polyester fiber exhibits a waste microfibers loss per gram of tested sample after a washing cycle of less than 10 mg of waste microfibers.
13. A textile comprising said melt-spun polyester fiber according to claim 1.
14. An article of manufacture comprising said melt-spun polyester fiber according to claim 1.
15. A method for forming said melt-spun polyester fiber according to claim 1, said method comprising melt spinning said poly(alkylene terephthalate) to thereby form said melt-spun polyester fiber.
16. A melt-spun polyester fiber for reducing microplastics pollution, wherein said melt-spun polyester fiber is in the form of:
(i) a first core-sheath bicomponent polyester fiber compiising a first core domain and a first sheath domain, wherein said first core domain comprises a poly(alkylene terephthalate) and said first sheath domain comprises a homopolyester or a copolyester that is different from said fiber-forming poly(alkylene terephthatate);
(ii) a second core-sheath bicomponent polyester fiber comprising a second core domain and a second sheath domain, wherein said second core domain comprises a poly(alkylene terephthalate) and said second sheath domain comprises a homopolyester or a copolyester and at least one shed-resistance additive; or (iii) a monocomponent polyester fiber comprising a poly(alkylene terephthalate), wherein said monocomponent polyester fiber is at least partially coated with a shed-resistance coating, wherein said melt-spun polyester fiber exhibits a fiber weight loss after a washing cycle of less than 2 weight percent, and wherein said melt-spun polyester fiber exhibits a waste microfibers loss per gram of tested sample after a washing cycle of less than 10 mg of waste microfibers.
(i) a first core-sheath bicomponent polyester fiber compiising a first core domain and a first sheath domain, wherein said first core domain comprises a poly(alkylene terephthalate) and said first sheath domain comprises a homopolyester or a copolyester that is different from said fiber-forming poly(alkylene terephthatate);
(ii) a second core-sheath bicomponent polyester fiber comprising a second core domain and a second sheath domain, wherein said second core domain comprises a poly(alkylene terephthalate) and said second sheath domain comprises a homopolyester or a copolyester and at least one shed-resistance additive; or (iii) a monocomponent polyester fiber comprising a poly(alkylene terephthalate), wherein said monocomponent polyester fiber is at least partially coated with a shed-resistance coating, wherein said melt-spun polyester fiber exhibits a fiber weight loss after a washing cycle of less than 2 weight percent, and wherein said melt-spun polyester fiber exhibits a waste microfibers loss per gram of tested sample after a washing cycle of less than 10 mg of waste microfibers.
17. The melt-spun polyester fiber according to claim 16, wherein said poly(alkylene terephthalate) comprises poly(1,2-ethylene terephthalate), poly(1,3-propylene terephthalate), or poly(1,4-butylene terephthalate), and wherein said homopolyester or said copolyester comprises poly(1,2-ethylene terephthalate), poly(1,3-propylene terephthalate), or poly(1,4-butylene terephthalate).
18. A textile comprising said melt-spun polyester fiber according to claim 16.
19. An article of manufacture comprising said melt-spun polyester fiber according to claim 16.
20. A method for forming said melt-spun polyester fiber according to claim 16, said method comprising melt spinning said poly(alkylene terephthalate) to thereby form said melt-spun polyester fiber.
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US201962885536P | 2019-08-12 | 2019-08-12 | |
PCT/US2020/045958 WO2021030456A1 (en) | 2019-08-12 | 2020-08-12 | Eco-friendly polyester fibers and microfiber shed-resistance polyester textiles |
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CA3147147A1 true CA3147147A1 (en) | 2021-02-18 |
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CA3147147A Pending CA3147147A1 (en) | 2019-08-12 | 2020-08-12 | Eco-friendly polyester fibers and microfiber shed-resistance polyester textiles |
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US (1) | US20210047756A1 (en) |
CN (1) | CN114364830A (en) |
CA (1) | CA3147147A1 (en) |
MX (1) | MX2022001752A (en) |
WO (1) | WO2021030456A1 (en) |
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JP6980839B2 (en) * | 2020-05-22 | 2021-12-15 | 伊藤忠ファッションシステム株式会社 | Microplastic emission evaluation method and product evaluation display method using it |
TWI789805B (en) * | 2021-06-30 | 2023-01-11 | 南亞塑膠工業股份有限公司 | Antibacterial and antifungal polyester material |
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JP2534272B2 (en) * | 1987-09-04 | 1996-09-11 | 株式会社クラレ | Manufacturing method of multi-component fiber entangled nonwoven fabric |
KR910003655B1 (en) * | 1989-06-24 | 1991-06-08 | 제일합섬 주식회사 | Preparation of polyester fibers having excellent antibacterial and decorizing properties |
US5607766A (en) * | 1993-03-30 | 1997-03-04 | American Filtrona Corporation | Polyethylene terephthalate sheath/thermoplastic polymer core bicomponent fibers, method of making same and products formed therefrom |
US5439741A (en) * | 1994-08-03 | 1995-08-08 | Hoechst Celanese Corporation | Heterofilament composite yarn |
JP3506521B2 (en) * | 1995-03-08 | 2004-03-15 | ユニチカ株式会社 | Biodegradable core-sheath composite long fiber and method for producing the same |
BR0013099A (en) * | 1999-08-06 | 2002-04-30 | Eastman Chem Co | Fiber, automotive article, and semicrystalline or crystalline polyester |
CA2385034C (en) * | 1999-09-17 | 2005-04-12 | Kanebo, Limited | Sheath-core composite conductive fiber |
US6548431B1 (en) * | 1999-12-20 | 2003-04-15 | E. I. Du Pont De Nemours And Company | Melt spun polyester nonwoven sheet |
US20040229540A1 (en) * | 2003-05-15 | 2004-11-18 | Kuraray Co. Ltd. | Dustproof clothing |
US7892993B2 (en) * | 2003-06-19 | 2011-02-22 | Eastman Chemical Company | Water-dispersible and multicomponent fibers from sulfopolyesters |
CN108239375B (en) * | 2016-12-23 | 2020-06-09 | 财团法人纺织产业综合研究所 | Wear-resistant fiber, wear-resistant and impact-resistant fiber and master batch thereof |
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- 2020-08-12 WO PCT/US2020/045958 patent/WO2021030456A1/en active Application Filing
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US20210047756A1 (en) | 2021-02-18 |
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