BIODEGRADATION-ENHANCED SYNTHETIC FIBER AND METHODS OF MAKING THE SAME

Abstract

The disclosure provides a synthetic biodegradation-enhanced fiber, methods of making such fiber, and articles including such fiber. The fiber includes a polymer material and 0.1 to 10 wt % one or more biodegradation additives at least partially contained within the polymer material. The biodegradation additives enhance the biodegradation rate of the polymer material in a biodegradation environment. The biodegradation additives may comprise at least one of an aliphatic-aromatic ester, a polylactide, an organoleptic, a monosaccharide, an aldohexose or a combination thereof. The synthetic fiber may be micro-denier fiber have a denier of less than or equal to 1, or macro-denier fiber having a denier greater than 1. The synthetic fiber may be siliconized.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Number 62/612,789, filed on Jan. 2, 2018, the entire contents of which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to biodegradation-enhanced synthetic fiber (e.g., biodegradation-enhanced polyester fiber), and to methods of forming biodegradation-enhanced synthetic fiber, insulation comprising biodegradation-enhanced synthetic fiber, and articles comprising biodegradation-enhanced synthetic fiber.

BACKGROUND OF THE INVENTION

Plastics, such as plastics in the polyester family, are industrially mass-produced and used widely throughout the world. For example, thermoplastic or thermoset polymer resins, such as resins including polyethylene, are used to form fibers for a myriad of different applications, containers for liquids and foodstuff, thermoforming for manufacturing, and in combination with other materials for engineering applications. The usage of synthetic plastics is increasing greatly year over year.

One reason plastic products are so widely used is their ability to withstand the forces of nature. For example, polyethylene polymers consist of long chains of carbon atoms, which are typically tightly intertwined, that are difficult to be broken down by microorganisms (e.g., bacteria, fungi or any other microscopic organism) that are normally responsible for degrading (i.e., biodegrading) material into water, carbon dioxide, methane and biomass (which is the expired microorganisms). While polyethylene polymers, such as those of the polyester family, may eventually degrade (e.g., biodegrade), they may only do so over a very long period of time. This same characteristic that makes plastics so attractive has led to serious environmental problems.

In recent years, environmental littering and destruction due to discarded plastic products has occurred at an alarming pace. In the clothing and/or textile industry, for example, it has become an increasing problem that such products formed by polyester or other plastic fibers end up in landfills or seawater/waterways. While some biodegradable plastics have been developed to attempt to mitigate or reduce the disposal problems of plastic products, such materials have not been suitable for fibers that are used to form high quality clothing and/or textile products. For example, a need still exists for insulative material for clothing and/or textile products formed from more eco-friendly materials.

While certain aspects of conventional technologies have been discussed to facilitate disclosure of Applicant's inventions, the Applicant in no way disclaims these technical aspects, and it is contemplated that their inventions may encompass one or more conventional technical aspects.

In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was, at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned.

SUMMARY OF THE INVENTION

Briefly, the present disclosure satisfies the need for improved fiber with beneficial degradable qualities. In various embodiments, the inventive fiber lends itself toward use in insulation that demonstrates improved biodegradation without undesirably decreasing the strength and/or insulative qualities of the insulation.

The present invention may address one or more of the problems and deficiencies of the art discussed above. However, it is contemplated that the invention may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the claimed invention should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.

In a first aspect, this disclosure provides a synthetic biodegradation-enhanced fiber. The fiber may comprise a polymer material (such as a polyester), and less than or equal to 10 wt % of a biodegradation additive that enhances the biodegradation rate of the polymer material. In some embodiments, the synthetic biodegradation-enhanced fiber may have a denier of 1 or less. In some embodiments, the synthetic biodegradation-enhanced fiber may have a denier of greater than 1. In some embodiments, the synthetic biodegradation-enhanced fiber may be siliconized.

In a second aspect, this disclosure provides insulation material comprising the biodegradation-enhanced synthetic fiber of the first aspect.

In a third aspect, this disclosure provides an article comprising the synthetic fiber of the first aspect, or the insulation material of the second aspect.

In a fourth aspect, this disclosure provides a method of making the synthetic biodegradation-enhanced fiber of the first aspect, the insulation material of the second aspect, and/or the article of the third aspect. The method of making the synthetic biodegradation-enhanced fiber, insulation material and/or article may comprise mixing biodegradation particles and a polymer material to form a biodegradation-enhanced polymer mixture, and extruding the biodegradation-enhanced polymer mixture into a fiber form. In some embodiments, the synthetic biodegradation-enhanced fiber may have a denier of 1 or less. In some embodiments, the synthetic biodegradation-enhanced fiber may have a denier of greater than 1. In some embodiments, the method may include performing one or more additional processing steps, such as siliconizing the synthetic biodegradation-enhanced fiber.

Certain embodiments of the presently-disclosed synthetic biodegradation-enhanced fiber, insulation and articles comprising the synthetic biodegradation-enhanced fiber, and methods of making the synthetic biodegradation-enhanced fiber have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the synthetic biodegradation-enhanced fiber, insulation, articles, and methods as defined by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section of this specification entitled “Detailed Description of the Invention,” one will understand how the features of the various embodiments disclosed herein provide a number of advantages over the current state of the art. For example, in some embodiments, the synthetic biodegradation-enhanced fiber provides improved biodegradation properties, thereby lending itself toward “environmentally friendly” fibers, monofilaments, fill, yarn, woven and nonwoven materials (e.g., insulation materials), articles (e.g., apparel, footwear, bedding, fabrics, mechanical belts and industrial products) and/or textiles. Embodiments of the synthetic biodegradation-enhanced fiber may be micro-denier or macro-denier synthetic (e.g., polyester) fiber with improved biodegradation properties, that may maintain, inter alia, a silky hand feel and heightened water repellency during normal use (e.g., before being discarded in a microbial biodegradation environment, such as in a landfill or seawater).

These and other features and advantages of this invention will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will hereinafter be described in conjunction with the following drawing figures, which are not necessarily drawn to scale for ease of understanding, wherein the same reference numerals retain their designation and meaning for the same or like elements throughout the various drawings, and wherein:

FIG. 1 is a side perspective view of a container with a mixture of biodegradation particles/additives and a polymer material according to certain embodiments of the present disclosure;

FIG. 2 is side view of a synthetic biodegradation-enhanced fiber according to certain embodiments of the present disclosure;

FIG. 3 is an enlarged view of a portion of a pellet embodiment containing a mixture of the polymer material and biodegradation particles;

FIG. 4 is a cross-sectional view of a portion of the synthetic biodegradation-enhanced fiber of FIG. 2; and

FIG. 5 is cross-sectional view a siliconized synthetic biodegradation-enhanced fiber according to certain embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the present inventions and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as to not unnecessarily obscure the inventions in detail. It should be understood, however, that the detailed description and the specific example(s), while indicating embodiments of the inventions, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions and/or arrangements within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.

Biodegradation is the degradation, disintegration, decay, breakdown or transformation of a material into innocuous products, particularly water, carbon dioxide, methane and biomass, by the action of living things, particularly microorganisms (e.g., bacteria, fungi or any other microscopic organisms) and enzymes secreted/produced thereby. Biodegradation may occur aerobically (with oxygen present) or anaerobically (without oxygen present). Decomposition of biodegradable substances may include both biological and abiotic steps.

In a first aspect, the invention provides a biodegradation-enhanced synthetic fiber comprising:

• • polymer material; and
  • less than or equal to 10 wt % biodegradation additive to enhance the biodegradation rate of the polymer material.

Denier is a unit of measure defined as the weight in grams of 9,000 meters of a fiber or yarn. It is a common way to specify the weight (or size) of the fiber or yarn. For example, traditional polyester fibers that are 1.0 denier typically have a diameter of approximately 10 micrometers. Micro-denier fibers are e those having a denier of 1.0 or less, while macro-denier fibers have a denier greater than 1.0.

The denier of the synthetic biodegradation-enhanced fibers of the present disclosure may be micro-denier fibers. For example, in some embodiments, the synthetic biodegradation-enhanced fiber may be micro-denier fibers with a denier equal to or less than 1. In some embodiments, the synthetic biodegradation-enhanced fibers may be micro-denier fibers with a denier less than 1.0, within the range of 0.5 to 1.0, or within the range of 0.7 to 0.9. In some embodiments, the synthetic biodegradation-enhanced fiber may be micro-denier fibers with a denier of 0.1 to 1.0 (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9 or 1.0), including any and all ranges and subranges therein. In some embodiments, the synthetic biodegradation-enhanced fiber may include a denier of 0.5 to 7, such as fibers utilized as staple fibers used as loose fill insulation.

In some embodiments, the biodegradation-enhanced synthetic fiber is a fiber with a denier (d) wherein 0.4≤d≤200 (e.g., d is 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, or 200 denier), including any and all ranges and subranges therein.

In some embodiments, the synthetic biodegradation-enhanced fibers are macro-denier fibers with a denier that is greater than 1.0 and less than or equal to 15.0, (for example, in some embodiments, the synthetic fiber has a denier of 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 10.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9 or 15.0), including any and all ranges and subranges therein (e.g., 1.1 to 15.0, 1.1 to 12.0, 1.1 to 10.0, 1.1 to 8.0, 1.1 to 6.0, 1.1 to 5.0, 1.1 to 4.0, 1.1 to 3.0, 1.1 to 2.0, etc.).

In some embodiments, the biodegradation-enhanced synthetic fiber is macro-denier monofilament fiber. In some embodiments, the denier of the biodegradation-enhanced synthetic monofilament fiber may be within the range of 3 to 1,000 (e.g., 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, 200, 225, 250, 275, 300, 325, 350, 375, 400, 425, 450, 475, 500, 525, 550, 575, 600, 650, 700, 750, 800, 850, 900, 950 or 1,000), including any and all ranges and subranges therein (e.g., 3 to 1,000, 3 to 600, 3 to 300, 3 to 200, 3 to 150, 3 to 75, 3 to 40, 3 to 30 or 3 to 20, etc.).

In some embodiments, the biodegradation-enhanced synthetic fiber may be monofilament fiber with a thickness (diameter) within the range of 0.5 mm to 6 mm (e.g., 0.5, 0.55, 0.6, 0.65, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, or 6.0 mm), including any and all ranges and subranges therein (e.g., 0.5 to 5 mm, 0.5 to 4 mm, 0.5 to 3 mm, 0.5 to 2 mm, 0.5 to 1.5 mm, 0.5 to 1.4 mm, 0.5 to 1.3 mm, 0.5 to 1.2 mm, 0.5 to 1.1 mm, 0.5 to 1.0 mm, 0.5 to 0.9 mm, 0.5 to 0.8 mm, 0.5 to 0.7 mm, etc.).

In some embodiments, the biodegradation-enhanced fibers are biodegradation-enhanced synthetic fibers. Persons having ordinary skill in the art are readily familiar with many synthetic fibers, and it is well within their purview to select an appropriate synthetic fiber depending on desired properties of the textile, fill, batting and/or article within which it is intended to be employed. Embodiments of the inventive biodegradation-enhanced fibers can comprise any synthetic fiber known in the art as being conducive to the preparation of textile materials. In some embodiments, nonexclusive synthetic biodegradation-enhanced fibers that may be used in the invention are selected from nylon, polyester, polypropylene, polylactic acid (PLA), poly(butyl acrylate) (PBA), polyamide (e.g., nylon/polyamide 6.6, polyamide 6, polyamide 4, polyamide 11, and polyamide 6.10, etc.), acrylic, acetate, polyolefin, rayon, lyocell, aramid, spandex, viscose, and modal fibers, and combinations thereof. In particular embodiments, synthetic biodegradation-enhanced fibers comprise polyester biodegradation-enhanced fibers. For example, in some embodiments, the polyester is selected from poly(ethylene terephthalate) (PET), poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate), poly-1,4-cyclohexelyne dimethylene (PCDT), polytrimethylene terephthalate (PTT), and terephthalate copolyesters in which at least 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units. In a particular embodiment, the polyester is polyethylene terephthalate. In some embodiments, the synthetic biodegradation-enhanced fibers comprise virgin polymer material, such as virgin polyester (e.g., PET). In some embodiments, the synthetic biodegradation-enhanced fibers comprise recycled polymer material (e.g., polyester, such a PET), such as post-consumer recycled (PCR) polymer material (e.g., polyester, such as PET).

In some embodiments, the biodegradation-enhanced fibers are dry fibers (i.e., non-slickened, e.g., non-siliconized fibers). In some other embodiments, the biodegradation-enhanced fibers are slickened fibers, e.g., siliconized fibers.

The synthetic biodegradation-enhanced fiber of the present disclosure may comprise at least 90 weight % polymer material. For example, in some embodiments, the synthetic biodegradation-enhanced fiber may comprise 90 to 99.9 wt% polymer material (e.g., 90.0, 90.1, 90.2, 90.3, 90.4, 90.5, 90.6, 90.7, 90.8, 90.9, 91.0, 91.1, 91.2, 91.3, 91.4, 91.5, 91.6, 91.7, 91.8, 91.9, 92.0, 92.1, 92.2, 92.3, 92.4, 92.5, 92.6, 92.7, 92.8, 92.9, 93.0, 93.1, 93.2, 93.3, 93.4, 93.5, 93.6, 93.7, 93.8, 93.9, 94.0, 94.1, 94.2, 94.3, 94.4, 94.5, 94.6, 94.7, 94.8, 94.9, 95.0, 95.1, 95.2, 95.3, 95.4, 95.5, 95.6, 95.7, 95.8, 95.9, 96.0, 96.1, 96.2, 96.3, 96.4, 96.5, 96.6, 96.7, 96.8, 96.9, 97.0, 97.1, 97.2, 97.3, 97.4, 97.5, 97.6, 97.7, 97.8, 97.9, 98.0, 98.1, 98.2, 98.3, 98.4, 98.5, 98.6, 98.7, 98.8, 98.9, 99.0, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9 wt % polymer material), including any and all ranges and subranges therein.

The synthetic biodegradation-enhanced fibers may comprise 0.1 to 15 wt % biodegradation particles or additives (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9, or 15.0 weight percent biodegradation particles), including any and all ranges and subranges therein (e.g., 0.1 to 10 wt %, 0.5 to 4.5 wt%, 0.1 to 3 wt %, 0.5 to 14.5 wt %, etc.).

In some embodiments, the synthetic biodegradation-enhanced fiber comprises 0.1 to 15 vol. % biodegradation particles or additives (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9, or 15.0 vol. %), including any and all ranges and subranges therein (e.g., 0.1 to 10 wt %, 0.5 to 4.5 wt%, 0.1 to 3 wt %, 0.5 to 14.5 wt %, etc.).

In some embodiments, the synthetic biodegradation-enhanced fiber of the present disclosure may comprise equal to or less than 10 weight % biodegradation particles or additives. For example, in some embodiments, the synthetic biodegradation-enhanced fiber may comprise equal to or less than 10.0, 9.9, 9.8, 9.7, 9.6, 9.5, 9.4, 9.3, 9.2, 9.1, 9.0, 8.9, 8.7, 8.6, 8.5, 8.4, 8.3, 8.2, 8.1, 8.0, 7.9, 7.8, 7.7, 7.6, 7.5, 7.4, 7.3, 7.2, 7.1, 7.0, 6.9, 6.7, 6.6, 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1, 3.0, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1, 2.0, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1 wt % biodegradation particles or additives, including any and all ranges and subranges therein.

Embodiments of the inventive biodegradation-enhanced synthetic fiber provide polymeric fibers within which biodegradation particles or additive(s) are embedded in polymer material. The biodegradation particles or additives may themselves be biodegradable and may also enhance and/or accelerate the biodegradation of the polymer material as compared to if the biodegradation particles are not present, as described above. In some embodiments, the biodegradation particles are homogenously mixed within the polymer material, meaning, the mixture of polymer material and biodegradation particles comprised within the synthetic fiber has a substantially uniform composition (i.e., 90-100% uniform composition, e.g., at least 90.0, 90.1, 90.2, 90.3, 90.4, 90.5, 90.6, 90.7, 90.8, 90.9, 91.0, 91.1, 91.2, 91.3, 91.4, 91.5, 91.6, 91.7, 91.8, 91.9, 92.0, 92.1, 92.2, 92.3, 92.4, 92.5, 92.6, 92.7, 92.8, 92.9, 93.0, 93.1, 93.2, 93.3, 93.4, 93.5, 93.6, 93.7, 93.8, 93.9, 94.0, 94.1, 94.2, 94.3, 94.4, 94.5, 94.6, 94.7, 94.8, 94.9, 95.0, 95.1, 95.2, 95.3, 95.4, 95.5, 95.6, 95.7, 95.8, 95.9, 96.0, 96.1, 96.2, 96.3, 96.4, 96.5, 96.6, 96.7, 96.8, 96.9, 97.0, 97.1, 97.2, 97.3, 97.4, 97.5, 97.6, 97.7, 97.8, 97.9, 98.0, 98.1, 98.2, 98.3, 98.4, 98.5, 98.6, 98.7, 98.8, 98.9, 99.0, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% uniform composition).

If the biodegradation particles include particles of differing materials, the differing biodegradation particles themselves may be of a substantially uniform composition (i.e., 90-100% uniform composition, e.g., at least 90.0, 90.1, 90.2, 90.3, 90.4, 90.5, 90.6, 90.7, 90.8, 90.9, 91.0, 91.1, 91.2, 91.3, 91.4, 91.5, 91.6, 91.7, 91.8, 91.9, 92.0, 92.1, 92.2, 92.3, 92.4, 92.5, 92.6, 92.7, 92.8, 92.9, 93.0, 93.1, 93.2, 93.3, 93.4, 93.5, 93.6, 93.7, 93.8, 93.9, 94.0, 94.1, 94.2, 94.3, 94.4, 94.5, 94.6, 94.7, 94.8, 94.9, 95.0, 95.1, 95.2, 95.3, 95.4, 95.5, 95.6, 95.7, 95.8, 95.9, 96.0, 96.1, 96.2, 96.3, 96.4, 96.5, 96.6, 96.7, 96.8, 96.9, 97.0, 97.1, 97.2, 97.3, 97.4, 97.5, 97.6, 97.7, 97.8, 97.9, 98.0, 98.1, 98.2, 98.3, 98.4, 98.5, 98.6, 98.7, 98.8, 98.9, 99.0, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% uniform composition).

In some embodiments, within the synthetic biodegradation-enhanced fiber, the biodegradation particles may be, for example, completely or at least partially covered by the polymer material. In some embodiments, at least 25% of the biodegradation particles present (e.g., greater than 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, or 95%) may be at least partially uncovered by the polymer material and/or at least partially exposed at an exterior surface of the polymer material. In some embodiments, at least 50% of the biodegradation particles within the biodegradation-enhanced synthetic fiber may be at least partially uncovered or exposed at an exterior surface of the polymer material.

The biodegradation particles or additive may include at least one organic compound. The biodegradation particles or additive may include at least one of an aliphatic-aromatic ester, a polylactide, an organoleptic, a monosaccharide, an aldohexose or a combination thereof. In some embodiments, the biodegradation additive may include at least one aliphatic-aromatic ester, at least one polylactide (PLA), at least one organoleptic, at least one monosaccharide, and at least one aldohexose. In some embodiments, the aliphatic-aromatic ester and/or the polylactide may act to bond at least one other biodegradation additive component to the polymer material (e.g., a polyester). For example, the aliphatic-aromatic ester and/or the polylactide may be a carrier resin for the other component(s) of the biodegradation additive. In some embodiments, the aliphatic-aromatic ester, and/or the polylactide may act a hydrolysis component to increase the hydrolytic quality of the polymer material and the fiber as a whole. The aliphatic-aromatic ester, polylactide and/or the polymer material chains may be split via hydrolysis by water, such as due to the scission of an ester bond. The aliphatic-aromatic ester and/or the polylactide (e.g., within the polymer material of the fiber) may facilitate acid hydrolysis, water hydrolysis and/or alkaline hydrolysis of the polymer material by chemical and/or enzymatic treatment. The aliphatic-aromatic ester and/or the polylactide (e.g., within the polymer material of the fiber) may also be susceptible to biological attack via an enzymatically catalysed hydrolysis of ester, amide or urethane bonds.

In some embodiments, the aliphatic-aromatic ester comprises poly[(1,4-butylene terephthalate)-co-(1,4-butylene adipate)] (poly[(tetramethylene terephthalate)-co-(tetramethylene adipate)]) (BTA). The aliphatic-aromatic ester component of the biodegradation additive may be formed at least one aliphatic dicarboxylic acid or ester thereof, at least one diol (such as, and not limited to, 1,4-butanediol and at least one polyfunctional aromatic acid (such as, and not limited to, furan dicarboxylic acid) or ester thereof. The aliphatic-aromatic ester component may have more than 60 mol percent aromatic acid content. In some embodiments, the aliphatic-aromatic ester component of the biodegradation additive may comprise an acid component (e.g., comprising an aromatic carboxylic acid and an aliphatic acid (e.g., azelaic acid) and a diol component (e.g., selected from the group consisting of C3, C4 and C6 diols). In some embodiments, the aliphatic-aromatic ester component of the biodegradation additive may comprise a polymerization reaction product of a dihydric alcohol, and an aromatic dicarboxy compound (e.g., an aromatic dicarboxylic acid, aromatic dicarboxylic (C1-3)alkyl ester, or a combination thereof), and an adipic acid.

The polylactide (PLA) component of the biodegradation additive may be one or more bioactive thermoplastic aliphatic polyester (e.g., derived from a renewable resource). In some embodiments, the polylactide component may comprise poly-L-lactide (PLLA), poly-D-lactide (PDLA), poly(L-lactide-co-D,L-lactide) (PLDLLA). As in known on the art, PLA may primarily degrade via abiotic hydrolysis. For example, degradation of PLA may occur in stages, the first being diffusion of water into the material, hydrolysis of ester bonds and lowering of molecular weight followed by intracellular uptake of lactic acid oligomers and catabolism. However, many differing microorganisms may also degrade PLA, such as proteases, actinomycetes, fungus and/or compost microorganisms.

The organoleptic component of the biodegradation additive may be configured to attract microorganisms present in an environment suitable for biodegradation that degrade (or cause degradation), or attract other microorganisms that degrade (or cause degradation), of the polymer material (and potentially the components biodegradation additive itself). For example, the organoleptic component of the biodegradation additive may be configured to attract one or more of the exemplary microorganisms discussed below. The organoleptic component of the biodegradation additive is configured to stimulate one or more sense organ of microorganisms (such as a taste, color, odor, or feel) to attract the microorganisms to the biodegradation-enhanced synthetic fiber and accelerate biodegradation.

In some embodiments, the organoleptic component of the biodegradation additive may comprise cultured colloids and natural or manmade fibers. The organoleptic component may comprise organoleptic organic chemicals as swelling agents i.e. natural fibers, cultured colloids, cyclo-dextrin, polylactic acid, etc. In some embodiments, the organoleptic component of the biodegradation additive may comprise a 3,5-dimethyl-pentenyl-dihydro-2(3H)-furanone isomer mixture. The organoleptic component nay be in the range equal to or greater than 0-20% by weight of the biodegradation additive. In some embodiments, the organoleptic component agent is 20-40%, 40-60%, 60-80% or 80-100% by weight of the total biodegradation additive.

The monosaccharide (and/or a polysaccharide) and/or aldohexose components of the biodegradation additive may act as food or consumable material for the microorganisms to attract microorganisms and/or maintain microorganism activity that, ultimately, causes the polymer material of the fiber (and thereby the fiber itself) to be broken down. In some embodiments, the monosaccharide may be glucose. In some embodiments, the monosaccharide may be D-glucose, D-galactose, and D-mannose. In some embodiments, the monosaccharide is D-glucose. In some embodiments, the monosaccharide and/or aldohexose components may be bonded to monomers of the polymer material of the fiber. In some embodiments, during formation of the fiber, at least some of the monosaccharide and/or aldohexose components may be substituted into the polymer.

The biodegradation particles or additive may facilitate or effectuate rapid biodegradation of the fiber (i.e., the polymer material thereof), even in an anaerobic environment. Specifically, the biodegradation additive may assist microorganisms in breaking down the polyester into CO₂, H₂O, CH₄, and biomass (which are the expired microorganisms) at a significantly faster rate than as compared to without the additives. For example, the biodegradation additive may allow initial microorganisms (or microbes) to consume C—C bonds within the polymer material at a macromolecular level which results in the consumption of the bonds. The initial microorganisms may thereby from indentations, caves, cavities or other open areas that extend into the polymer material of the fiber. In this way, the additives and the initial microorganisms create a greater or increased exposed surface area of the polymer, allowing plastophilic microbes to attach themselves thereto within the openings of the polymer (rather than only on the exterior surface of the polymer). The biodegradation rate of the polymer material is thereby increased or advanced.

However, the biodegradation additive may increase the biodegradation rate of the polymer material, as compared to the biodegradation rate thereof without the additive, in diverse ways. For example, the additive may increase the hydrolysis/condensation stage of the biodegradation of the fiber, the acidogenesis stage of the biodegradation of the fiber, the acetogenesis stage of the biodegradation of the fiber, the methanogenesis stage of the biodegradation of the fiber, or a combination thereof. As noted above, the biodegradation additive may increase the hydrolytic quality of the fiber (or polymer material). Hydrolysis may tend to break down the chains of the polymer material, and thereby cause condensation (i.e., the build-up of water). The hydrolysis/condensation stage of the fiber/polymer material, effectuated or more rapidly effectuated by the biodegradation additive, may break down the polymer material of the fiber into various sugars.

In the acidogenesis stage of the biodegradation of the fiber, acidogenic microorganisms may breakdown the organic matter or biomass resulting from the hydrolysis/condensation stage, other biomass of the polymer material and/or the additive. The acidogenic microorganisms (e.g., fermentative bacteria) may produce an acidic environment while creating various acids, alcohols and volatile fatty acids, such as ammonia, H₂, CO₂, H₂S, short volatile fatty acids, carbonic acids, trace amounts of other byproducts, or a combination thereof. The acidogenic microorganisms may thereby produce partially-broken down biomass of/from the polymer material.

During the acetogenesis stage of the biodegradation of the fiber, microorganisms may further breakdown the biomass of/from the polymer material in to acetic acid, carbon dioxide, hydrogen, or a combination thereof. For example, acetogenesic microorganisms, such as acetogens, may convert the biomass into acetate from carbon and other energy sources. The acetogenesic microorganisms or acetogens may break down the biomass to a point to which methanogenic microorganisms can utilize much of the remaining polymer material. For example, during the methanogenesis stage of the biodegradation of the fiber, methanogenic microorganisms or methanogens may breakdown the biomass of/from the polymer material (and potentially some of the intermediate products from hydrolysis and acidogenesis stages) into methane, water, and carbon dioxide, or a combination thereof. In some embodiments, the methanogenic microorganisms may utilize acetic acid and carbon dioxide (the two main products from the hydrolysis/condensation stage, acidogenesis stage and acetogenesis stage) to create methane in methanogenesis. For example, the methanogens may utilize CO₂ and H₂ to form CH₄ and H₂O. As another example, the methanogens may utilize CH₃COOH to form CH₄ and CO₂. While the CO2 may be converted into methane and water through the reaction, the main mechanism to create methane in methanogenesis may be the path involving acetic acid. In some embodiments, the acetic acid path may create methane and CO₂. Further, as the biomass of the fiber/polymer material dissipates, the microorganism themselves may die off and thereby create further biomass.

In some embodiments, the synthetic biodegradation-enhanced fibers of the present disclosure more quickly biodegrade as compared to fibers having similar compositions but lacking the biodegradation particles. For example, the synthetic biodegradation-enhanced fibers of the present disclosure may fully biodegrade (e.g., be converted to water, carbon dioxide, methane and biomass or a combination thereof) within 10 years when disposed in an environment suitable for biodegradation (aerobic or anaerobic), such as in a landfill, compost pile/facility, seawater/waterway or other bioactive environment/material that includes microorganisms that will break down the polymer of the fibers.

In some embodiments, the synthetic biodegradation-enhanced fibers of the present disclosure may fully biodegrade within about 9.5, 9, 8.5, 8, 7.5, 7, 6.5 or 6 years when disposed in an environment suitable to biodegradation (i.e., includes microorganisms that consume or otherwise break down the materials of the synthetic fiber into water, carbon dioxide, methane or a combination thereof. In some embodiments, at least 25% by mass of the synthetic biodegradation-enhanced fibers of the present disclosure may biodegrade within about 3, 2.5, 2 or 1.5 years when disposed in an environment suitable to biodegradation.

In some embodiments, the synthetic biodegradation-enhanced fiber of the present disclosure (or an article comprising the fibers) meets or exceeds the standards for biodegradability as determined according to ASTM D6400-12, Standard Specification for Labeling of Plastics Designed to be Aerobically Composted in Municipal or Industrial Facilities, ASTM International, West Conshohocken, Pa., 2012, which is hereby incorporated herein by reference).

In some embodiments, the synthetic biodegradation-enhanced fiber of the present disclosure may be siliconized. The term “siliconized” is used herein to refer to a fiber that is coated with a silicon-comprising composition (e.g., a silicone). Siliconization techniques are well known in the art, and are described, e.g., in U.S. Pat. No. 3,454,422. The silicon-comprising composition may be applied using any method known in the art, e.g., spraying, mixing, dipping, padding, etc. the fiber. The silicon-comprising (e.g., silicone) composition, which may include an organosiloxane or polysiloxane, bonds to an exterior portion of the fiber. The silicon-comprising (e.g., silicone) composition may thereby extend fully about the polymer material and the biodegradation additives contained at least partially within the polymer material. The silicon-comprising (e.g., silicone) composition may be void of the biodegradation additives.

In some embodiments, the silicone coating is a polysiloxane such as a methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane, or amino modified dimethylpolysiloxane. As is known in the art, the silicon-comprising composition may be applied directly to a fiber, or may be diluted with a solvent as a solution or emulsion, e.g. an aqueous emulsion of a polysiloxane, prior to application. Following treatment, the coating may be dried and/or cured. As is known in the art, a catalyst may be used to accelerate the curing of the silicon-comprising composition (e.g., polysiloxane containing Si—H bonds) and, for convenience, may be added to a silicon-comprising composition emulsion, with the resultant combination being used to treat the synthetic biodegradation-enhanced fiber. Suitable catalysts include iron, cobalt, manganese, lead, zinc, and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates. In some embodiments, following siliconization, the fiber may be dried to remove residual solvent and then optionally heated to between 65° and 200° C. to cure.

The synthetic biodegradation-enhanced fiber may be crimped or uncrimped. Various crimps, including spiral (i.e., helical) and standard crimp, are known in the art. The synthetic biodegradation-enhanced fiber may have any desired crimp.

In some embodiments, the synthetic biodegradation-enhanced fiber is a staple fiber (i.e., a fiber having a standardized length). For example, in some embodiments, the synthetic biodegradation-enhanced fiber is a staple fiber having a length of 5 to 120 mm (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, or 120 mm), including any and all ranges and subranges therein (e.g., 8 to 85 mm). In some embodiments, a plurality of such staple fibers may be combined or provided together. As another example, in some embodiments, the synthetic biodegradation-enhanced fiber is a staple fiber having a length of 8 to 51 mm (and potentially deniers of 0.5 to 7) for loose fill insulation.

In some embodiments, the synthetic biodegradation-enhanced fiber is a filament. A filament is a single long threadlike continuous textile fiber/strand. Unlike staple fibers, which are of finite length, filaments are of indefinite length, and can run for yards or miles (or e.g., where employed in yarn, can run the entire length of yarn). In some embodiments, the filament ranges in length from 5 inches to several miles, including any and all ranges and subranges therein. For example, in some embodiments, the filament may be at least 5 inches in length (e.g., at least 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 inches in length, or any range or subrange therein). In some embodiments, the filaments may be at least 1 foot in length (e.g., at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, or 1000 feet in length, or any range or subrange therein).

Filaments may be created by a process known as extrusion (which can also be called melt spinning). For example, in some embodiments, after mixing biodegradation particles and the polymer material, the resultant biodegradation-enhanced polymer mixture may be extruded as an biodegradation-enhanced polymer pellet. Subsequently, depending on desired biodegradation particle loading, a plurality of pellets, including at least the biodegradation-enhanced polymer pellet, may be extruded into fiber. For example, pellets can be extruded through well-known techniques, such as by bringing them to or beyond their melting point, thereby forming liquid biodegradation-enhanced polymer mixture, then forcing the liquid biodegradation-enhanced polymer mixture through a dye called a spinneret. The spinneret often has many small holes through which the liquid passes. The liquid polymer streams are cooled upon exiting the spinneret, resulting in long strands of continuous synthetic biodegradation-enhanced fibers. The extruded filaments may optionally be combined with those of another (e.g., an adjoining) spinneret to increase the number of filaments in a bundle. A bundle of filaments maybe drawn (stretched) to make each filament thinner, and may optionally be texturized, as described below.

Alternatively, the extruded filaments may not be combined with one or more other filament and thereby configured/utilized as a monofilament (i.e., a single, continuous synthetic biodegradation-enhanced filament (or strand)). The monofilament fibers may be utilized as single strand filaments or as a plurality of strands of fiber.

Texturizing techniques may be performed on filament bundles (used, e.g., in yarn) to disrupt the parallelization of the filaments, and used on monofilaments to texturize the monofilaments. Such techniques may serve, for example, to add bulk without adding weight, which can make the resultant yarn seem lighter in weight, have improved hand-feel (softness), appear more opaque, and/or have improved temperature insulating properties. While any art-acceptable texturizing processes may be employed, examples of texturizing processes conducive to use in the invention include crimping, looping, coiling, crinkling, twisting then untwisting and knitting then deknitting.

In some embodiments, the synthetic biodegradation-enhanced fiber may be void of a lubricious additive, such as that disclosed in U.S. Pat. No. 3,324,060.

In some embodiments, the synthetic biodegradation-enhanced fibers may be configured as high-melt or non-bonding (or non-binder) fibers, such as fibers with a bonding temperature greater than 200° C. Generally speaking, high-melt or non-bonding fibers have a bonding temperature higher than the softening temperature of other synthetic fibers present in a fiber mixture. In some embodiments, the synthetic biodegradation-enhanced fibers may be configured as bonding fibers, such as fibers with a bonding temperature less than or equal to 200° C. Generally speaking, binder fibers have a bonding temperature lower than the softening temperature of other synthetic fibers present in a fiber mixture. In some such embodiments, the synthetic biodegradation-enhanced binder fibers have a bonding temperature of less than or equal to 200° C. In some embodiments, the synthetic biodegradation-enhanced binder fibers have a bonding temperature of 50 to 200° C. (e.g., 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, or 200° C.), including any and all ranges and subranges therein. In some embodiments, the synthetic biodegradation-enhanced binder fibers have a bonding temperature of 80° C. to 150° C. In some embodiments, the synthetic biodegradation-enhanced binder fibers have a bonding temperature of 100° C. to 125° C. In some embodiments, the synthetic biodegradation-enhanced binder fibers comprise low-melt polyester fibers. In some embodiments, the synthetic biodegradation-enhanced binder fibers are bicomponent fibers comprising an exterior and interior (commonly known in the art as a sheath and core), wherein the exterior comprises a material having a lower melting point than the interior. In other embodiments, the synthetic biodegradation-enhanced binder fibers are monocomponent fibers.

In some embodiments, the synthetic biodegradation-enhanced fiber additionally comprises one or more additional additives. For example, in some embodiments, the synthetic fiber additionally comprises aerogel. For example, in some embodiments, the synthetic fiber additionally comprises aerogel particles, as in, e.g., the synthetic fiber described in International Application Publication No. WO 2017/087511. For example, in some embodiments, the inventive fiber comprises 0.1 to 15 wt % aerogel particles, including any and all ranges and subranges therein (e.g., 1 to 10 wt %, 0.5 to 4.5 wt%, 1 to 4.5 wt %, 2 to 4.5 wt %, etc.), said aerogel particles having an average diameter of 0.3 to 20 μm, including any and all ranges and subranges therein (e.g., 0.8 to 2 μm).

Persons having ordinary skill in the art will readily appreciate that there are many applications within which the inventive synthetic biodegradation-enhanced fiber may be advantageously employed. Indeed, embodiments of the synthetic biodegradation-enhanced fiber and insulation according to the invention find use in many different industries. Non-limiting examples include use in: textile fabrics, e.g., paper machine clothing, porous and/or non-porous textile mechanical belts, wet filters/filtration, dry filter/filtration, etc. (where the fiber could be used as, e.g., a monofilament); refrigerated trucks; pipelines (e.g., petrochemical pipelines); aerospace applications (e.g., aerospace insulation panels); cryogenic storage tanks; fuel cells; car battery (e.g., electric car battery) protection; mechanical textile belts (wet; any other fabric, fabric-like or insulative applications, etc. In some embodiments, when configured as a monofilaments (or filament bundle), the synthetic biodegradation-enhanced fiber and insulation according to the invention may be utilized as/in electrical cables and cable assemblies, 3D printer filament, fishing line, eyewear retainers, industrial fastening systems, thread, woven or knitted narrow fabrics, interlayer material (e.g., in double wall tanks or the like), braided reinforcement for cables and/or tubing, knitting needle cables, wet/liquid filters (e.g., water filters/filtration), dry/gas filters (air filters), braided ropes and cords, mist eliminators/stack scrubbers, woven flexible conduit, netting, dental applicators, automobile or industrial fabrics, waistbands, brushes/brooms, weather seals, medical devices, ultra-violet stabilized fabrics, infusion flow reinforcement textiles, hook and loop fastening systems, mesh, whisker disks, etc.

In a second aspect, the invention provides insulation material comprising the synthetic biodegradation-enhanced fiber.

In some such embodiments, the insulation material may comprise synthetic biodegradation-enhanced non-binder fibers. In some embodiments, the insulation material may comprise synthetic biodegradation-enhanced binder fibers (and potentially synthetic non-biodegradation-enhanced binder fibers). In some such embodiments, the insulation material may be heat treated so as to melt all or a portion of the binder fibers, thereby forming a thermally bonded insulation. Persons having ordinary skill in the art will understand that, in such embodiments, although binder fibers are included in the fiber mixture, said fibers may be wholly or partially melted fibers, as opposed to binder fibers in their original, pre-heat treatment form.

Persons having ordinary skill in the art will appreciate that the biodegradation-enhanced fiber of the present disclosure may generally be used in place of or in supplement to synthetic or natural fiber used in or as insulation material.

In some embodiments, the insulation material is fabric, fleece, a pad, blowable insulation material, a non-woven web, vertically lapped batting or horizontally lapped batting. In some embodiments, the insulation material is textile insulation material (i.e., insulation material used in the textile field).

In some embodiments, the insulation material is blowable insulation or filling material, comprising a plurality of discrete, longitudinally elongated floccules each formed of a plurality of synthetic biodegradation-enhanced fibers according to the first aspect of the invention, the floccules including a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion. For examples, in some embodiments, the insulation material is a blowable floccule insulation as described in International Application Publication No. WO 2017/058986, which comprises the synthetic biodegradation-enhanced fiber.

In some embodiments, the invention provides batting comprising the synthetic biodegradation-enhanced fiber. In some embodiments, the batting has a thickness of 1 mm to 160 mm (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, or 160 mm), including any and all ranges and subranges therein. In some embodiments, the thickness is less than or equal to 40 mm, e.g., 2 to 40 mm. In some embodiments, the batting has a density of 1 to 10 kg/m3 (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 kg/m3), including any and all ranges and subranges therein. In some embodiments, the batting range in weights from 25 GSM to 200 GSM.

In some embodiments, the invention provides yarn comprising the synthetic biodegradation-enhanced fibers woven, knitted, twisted, braided or otherwise combined. Such yarn may be utilized to form a biodegradation-enhanced textile or other biodegradation-enhanced article from the fibers.

Clo (clo/oz/yd²) is a unit used to measure the thermal resistance of clothing. A value of 1.0 clo is defined as the amount of insulation that allows a person at rest to maintain thermal equilibrium in an environment at 21° C. (70° F.) in a normally ventilated room (0.1 m/s air movement). Typically, above this temperature the person so dressed will sweat, whereas below this temperature the person will feel cold. Clothing and/or its components can be assigned a do value. Higher do indicates an article is warmer than another article with a comparatively lower clo.

In some embodiments, insulation (e.g. as batting, loose fill, etc.) comprising the synthetic biodegradation-enhanced fiber has a thermal performance rating of at least 0.80 clo/oz/yd². In some embodiments, the insulation has a thermal performance rating of at least 1.0 clo/oz/yd².

In a third aspect, the invention provides an article comprising the synthetic biodegradation-enhanced fiber of the first aspect of the invention, or the insulation material of the second aspect of the invention.

In some non-limiting embodiments, the article is an article of footwear (e.g., shoes, socks, slippers, boots), outerwear (e.g. outerwear garments such as a jacket, coat, shoe, boot, pants (e.g., snow pants, ski pants, etc.) glove, mitten, scarf, hat, etc.), clothing/apparel (e.g., shirts, pants, undergarments (e.g., underwear, thermal underwear, socks, hosiery, etc.), sleepwear (e.g., pajamas, nightgown, robe, etc.)), active wear (e.g., clothing, including footwear, worn for sport or physical exercise), sleeping bag, bedding (e.g., comforter), pillow, cushion, pet bed, home good, etc. In some embodiments, the synthetic biodegradation-enhanced fiber is comprised within at least a part of one of the articles listed above.

In a fourth aspect, the invention provides a non-limiting method of making the synthetic biodegradation-enhanced fiber or an article comprising the synthetic biodegradation-enhanced fiber (e.g., clothing, insulation material, etc.). The method may comprise:

• • mixing the biodegradation particles and the polymer material, thereby forming a biodegradation-enhanced polymer mixture;
  • extruding the biodegradation-enhanced polymer mixture; and
  • optionally performing one or more additional processing steps, thereby forming the synthetic biodegradation-enhanced fiber or article.

In some embodiments, the one more additional processing steps may include siliconizing the biodegradation-enhanced fiber. In some embodiments, method may include, for example, obtaining raw, pure or “new” polymer. In some alternative embodiments, the process may make use of recycled or waste polymer (e.g., leftover polymer from other processes or polymer from other products). In some of such embodiments, the method may optionally include purifying the recycled or waste polymer to remove contaminants from the recycled or waste polymer. Once contaminants are removed, the recycled or waste polymer may be combined with the biodegradation particles.

The biodegradation-enhanced polymer mixture may be directly extruded into fiber. In other embodiments, the biodegradation-enhanced polymer mixture may be extruded or otherwise formed into an intermediary product (e.g., pellets) that can later be used to make fiber. Where an intermediary product (e.g., pellet) is made, the intermediary product may optionally later be mixed with other material (e.g., other polymer material or other pellets that comprise a different or further biodegradation particles, or no biodegradation particles) so as to control and achieve a desired loading percent of biodegradation particles in subsequently-formed fiber.

Embodiments of the inventive method comprise forming fiber, either directly from the biodegradation-enhanced polymer mixture, or from the intermediary products (e.g., pellets), using appropriate textile fiber production methods, as are well known in the art. The textile fiber production method may include, for example, melt spinning, wet spinning, dry spinning, gel spinning, electro spinning, and the like as known in the art. For example, a mixture (e.g., the biodegradation-enhanced polymer mixture, or a mixture containing the intermediary products—for example, a mixture comprising melted intermediary products and optionally one or more other materials) may be extruded through spinnerets to form continuous filaments. The continuous filaments may then be manipulated by, for example, drawing, texturizing, crimping, and/or cutting, or another known method in the art, to form fibers in the most usable form for their final application. The continuous filaments may be cut to a specific length and packaged into a bale. The bale may then be sent, e.g., to a yarn spinner that processes the staple fibers into yarn (which could be further processed, e.g., for use in apparel like base layer garments). In some embodiments, the fibers may be carded and lapped (horizontally or vertically) into non-woven insulative batting.

In some embodiments, the biodegradable additive is introduced into a polymer material (e.g., polyethylene, such as PET), and, once mixed, the biodegradation-enhanced polymer mixture may be extruded into pellets, which may be referred to as a “master batch”. Next, the master batch can be transferred to a manufacturer for extruding (e.g., melt blown spinning). The master batch may be used (e.g., melted and extruded) to produce the synthetic biodegradation-enhanced fibers. Alternatively, the master batch may be combined with pellets of other formulations to produce a desired mixture than can be used to produce the synthetic biodegradation-enhanced fibers.

Processing steps undertaken to form the synthetic biodegradation-enhanced fiber or insulation or articles comprising the synthetic biodegradation-enhanced fiber can differ depending on the fiber that is intended to be formed. For example, in some embodiments, the inventive process forms a continuous filament by, e.g., drawing (and potentially texturizing and/or adding one or more desired finish chemistries). In some embodiments, the method forms staple fibers by, e.g., drawing, cutting, optionally crimping, and optionally adding one or more desired finish chemistries. In some embodiments, the method forms monofilament fibers by, e.g., drawing and winding the filaments as single, continuous strands. It is contemplated that any desired finish chemistries may be used in accordance with the invention. Finish chemistries are well known in the art and include, e.g., siliconization, durable water repellency treatment, etc.

The synthetic biodegradation-enhanced fibers may form and/or be incorporated into articles (e.g., end products), for example, garments, fabric, insulation, monofilaments, yarn, etc. In some embodiments, the articles or insulation with the biodegradation-enhanced fiber more quickly biodegrade than similar articles or insulation without the biodegradation-enhanced fibers. The synthetic biodegradation-enhanced fiber and/or articles or insulation made with the inventive synthetic biodegradation-enhanced fiber may have a first full or partial (e.g., 25%, 50%, 75%) biodegradation rate BR₁ (e.g., by mass) while synthetic biodegradation-enhanced fiber and/or articles or insulation made of non-biodegradation-enhanced polymer fibers may have a respective second full or partial (e.g., 25%, 50%, 75%) biodegradation rate BR₂ that is substantially slower/smaller than the first biodegradation rate BR₁. In some embodiments, the first biodegradation rate BR₁ may be at least 50% faster or 100% faster (i.e., twice as fast) than the second biodegradation rate BR₂, such as at least 50%, 75%, 100%, 150%, 200%, 300%, 400%, 500%, 600%, 700%, 800%, 900%, 1,000%, 1,100%, 1,200%, 1,300% , 1,400% or 1,500% faster that than the second biodegradation rate BR2.

With reference to FIGS. 1-5, an embodiment of a synthetic (e.g., polyester) biodegradation-enhanced fiber 130 as described in greater detail above, and a method of making such a fiber, is shown. The method may include obtaining a polymer material 110 (depicted within a container 100 as shown in FIG. 1). The polymer material 110, such as polyester, may be mixed with biodegradation additives or particles 120 to form a biodegradation-enhanced polymer mixture, as shown in FIG. 1. The biodegradation particles 120 may thereby be mixed, such as substantially homogenously, within the polymer material 110. The mixture may be extruded into fiber 130 (which may be a filament or may be cut to staple fiber) as shown in FIGS. 2, 4, and 5, or formed into pellets 140 as shown FIG. 4, as described in greater detail above and shown in FIGS. 2-5. Where the mixture is melt-extruded into pellets, the pellets may subsequently be extruded into the fibers 130.

An embodiment of the inventive synthetic biodegradation-enhanced fiber 130 is illustrated in FIGS. 2, 4, and 5. As shown, the polymer material 110 of the synthetic biodegradation-enhanced fiber 130 contains a plurality of biodegradation particles or additives 120 dispersed throughout the polymer material 110. The biodegradation particles 120 may be homogeneously distributed throughout the polymer material 110. Although FIGS. 2-5 show the biodegradation particles 120 completely embedded into the polymer material 110, it is also contemplated that in some instances the biodegradation particles 120 may be only at least partially embedded into the polymer material 110.

As shown in FIG. 4, the synthetic biodegradation-enhanced fiber 130 may contain a plurality of biodegradation particles 120 dispersed throughout the polymer material 110 of the fiber 130. The biodegradation particles 120 may be homogeneously distributed throughout the polymer material 110 and fiber 130, as shown. As shown in FIG. 4, the biodegradation particles 120 may be present at the exterior of the polymer material 110 (and potentially the fiber 130 itself) so that microorganisms are able to consume the biodegradation particles 120 and form the caves, cavities, tunnels or apertures within the interior of the polymer material 110 to enhance the biodegradation rate thereof, as explained above.

As shown in FIG. 5, the fiber 130 may be siliconized such that the silicon-comprising material 150 may extend about the polymer material 110 and the biodegradation particles 120. In this way, microorganisms may consume or otherwise cause the silicon-comprising material 150 to separate from the polymer material 110 and the biodegradation particles 120 to thereby expose the biodegradation particles 120. The microorganisms may thereby be able to consume the biodegradation particles 120 and form the caves, cavities, tunnels or apertures to enhance the biodegradation rate thereof, as explained above.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), “contain” (and any form contain, such as “contains” and “containing”), and any other grammatical variant thereof, are open-ended linking verbs. As a result, a method or article that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of an article that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

As used herein, the terms “comprising,” “has,” “including,” “containing,” and other grammatical variants thereof encompass the terms “consisting of” and “consisting essentially of.”

The phrase “consisting essentially of” or grammatical variants thereof when used herein are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed compositions or methods.

All publications cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein as though fully set forth.

Subject matter incorporated by reference is not considered to be an alternative to any claim limitations, unless otherwise explicitly indicated.

Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

While several aspects and embodiments of the present invention have been described and depicted herein, alternative aspects and embodiments may be affected by those skilled in the art to accomplish the same objectives. Accordingly, this disclosure and the appended claims are intended to cover all such further and alternative aspects and embodiments as fall within the true spirit and scope of the invention.

Claims

1. A synthetic biodegradation-enhanced fiber comprising:

a polymer material; and

0.1 to 10 wt % of one or more biodegradation additives at least partially contained within the polymer material that enhance the biodegradation rate of the polymer material in a biodegradation environment, said biodegradation additive comprising at least one of an aliphatic-aromatic ester, a polylactide, an organoleptic, a monosaccharide, an aldohexose or a combination thereof.

2. The synthetic biodegradation-enhanced fiber according to claim 1, comprising at least 85% of the polymer material.

3. The synthetic biodegradation-enhanced fiber according to claims 1, wherein the polymer material comprises polyester.

4. (canceled)

5. The synthetic biodegradation-enhanced fiber according to claim 1, wherein the biodegradation additive comprises at least one aliphatic-aromatic ester, at least one polylactide, at least one organoleptic, at least one monosaccharide and at least one aldohexose.

6. The synthetic biodegradation-enhanced fiber according to claim 5, wherein the synthetic fiber is siliconized.

7. The synthetic biodegradation-enhanced fiber according to claim 6, wherein the siliconizing material is void of the one or more biodegradation additives.

8. The synthetic biodegradation-enhanced fiber according to claim 1, wherein the one or more biodegradation additives are homogenously dispersed within the polymer material.

9. The synthetic biodegradation-enhanced fiber according to claim 1, comprising 0.5 to 3 wt % of the one or more biodegradation additives.

10. (canceled)

11. The synthetic biodegradation-enhanced fiber according to claim 1, having a denier of less than or equal to 1.

12. (canceled)

13. The synthetic biodegradation-enhanced fiber according to claim 1, wherein the fiber meets or exceeds the standards for biodegradability as determined according to ASTM D6400-12.

14-18. (canceled)

19. The synthetic biodegradation-enhanced fiber according to claim 1, wherein the fiber is a staple fiber having a length of 5 to 120 mm.

20. (canceled)

21. (canceled)

22. Insulation material comprising the synthetic biodegradation-enhanced fiber according to claim 1.

23. (canceled)

24. An article comprising the synthetic biodegradation-enhanced fiber according to claim 1.

25. The article according to claim 24, wherein said article is selected from the group consisting of an outerwear product, footwear, clothing, a sleeping bag, bedding and an industrial textile.

26. A synthetic biodegradation-enhanced fiber comprising:

a polymer material;

0.1 to 10 wt % of one or more biodegradation additives at least partially contained within the polymer material that enhance the biodegradation rate of the polymer material in a biodegradation environment, said biodegradation additives comprising at least one of an aliphatic-aromatic ester, a polylactide, an organoleptic, a monosaccharide, an aldohexose or a combination thereof; and

a silicon coating extending about the polymer material and biodegradation additives.

27. The synthetic biodegradation-enhanced fiber according to claim 26, comprising at least 85% of the polymer material.

28. The synthetic biodegradation-enhanced fiber according to claim 26, wherein the polymer material comprises polyester.

29. (canceled)

30. The synthetic biodegradation-enhanced fiber according to claim 26, wherein the biodegradation additives comprise at least one aliphatic-aromatic ester, at least one polylactide, at least one organoleptic, at least one monosaccharide and at least one aldohexose.

31. The synthetic biodegradation-enhanced fiber according to claim 26, wherein:

the one or more biodegradation additives are homogenously dispersed within the polymer material;

the silicon coating is void of the biodegradation additives; and

the synthetic biodegradation-enhanced fiber comprises 0.5 to 3 wt % of the one or more biodegradation additives.

32-49. (canceled)

50. A method of making the synthetic biodegradation-enhanced fiber according to claim 1, said method comprising:

mixing the one or more biodegradation additives and the polymer material, thereby forming a biodegradation-enhanced polymer mixture; and

extruding the biodegradation-enhanced polymer mixture; and

optionally performing one or more additional processing steps, thereby forming the synthetic fiber.

51-57. (canceled)