FILAMENTS WITH IMPROVED LUSTER

Abstract

Various implementations of yarns and multi-component filaments having a plurality of solid particles dispersed throughout a portion of the filaments are described herein. Inclusion of solid particles through a portion of the filaments allows for differing certain properties in products formed from the filaments while maintaining desirable physical properties such as strength or abrasion resistance. For example, including translucent or transparent particles, such as glass flakes or mica, may differ the visual properties, such as providing an increased luster. And, in other implementations, opaque solid particles may be included through a portion of the filaments to create a different property for a product formed with the filament.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/116,334, filed Nov. 20, 2020, the content of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to polymeric filaments, and more particularly to multi-component filaments with enhanced luster that may find use in the production of yarns.

BACKGROUND

Within the textile industry, and particularly the carpet industry, consumers increasingly demand products that show more interesting and complex visual properties. The luster of the filaments used in manufacture is one property that impacts the visual aspect of textile products. Typically, manufacturers adjust the luster properties of a filament by adjusting the composition or shape of the filament. While products having a higher luster may be desirable for their visual properties, they may be considered impractical in some applications due to their propensity to more readily show soiling compared to more matte products. In many applications, a delusterant such as titanium dioxide may instead be added to provide a more matte finish to the product. Further, many filaments that naturally have higher luster, such as silk, are also more prone to wear from use. Thus, there is a clear need for new products for use in textiles that show enhanced luster while also showing enhanced strength and stain resistance properties.

SUMMARY

The present disclosure provides yarns and multi-component filaments having a plurality of solid particles dispersed throughout a portion of the filaments. Inclusion of solid particles through a portion of the filaments, in particular translucent or transparent particles such as glass flakes or mica, allow for differing visual properties in products formed from the filaments, such as an increased luster, while maintaining desirable physical properties such as strength or abrasion resistance.

According to a first aspect, a multi-component filament is provided comprising a first component comprising a first polymer and a second component comprising a second polymer and a plurality of solid particles dispersed within the second polymer, wherein the second component forms at least 50 percent of an external (or outermost) surface area of the multi-component filament. In some embodiments, the multi-component filament is a bicomponent filament.

In some embodiments, the first component comprises a core and the second component comprises a sheath, wherein the sheath encapsulates the core.

In some embodiments, the solid particles are evenly dispersed in the second polymer.

In some embodiments, the first component may further comprise a plurality of solid particles dispersed in the first polymer, the plurality of solid particles having a concentration by volume in the first polymer that is less than a concentration by volume of the particles of the second polymer. In some embodiments, the solid particles are evenly dispersed in the first polymer.

In some embodiments, the solid particles may be transparent or translucent. In some embodiments, the solid particles may comprise glass flakes. In some embodiments, the glass flakes have an average particle diameter ranging from 5 microns to 35 microns. In some embodiments, the glass flakes have an average thickness ranging from 0.5 microns to 8 microns. In some embodiments, the glass flakes are surface treated with a coating, for example a silane coating. In some embodiments, the glass flakes may be present in a concentration of at least 10% by volume within the second polymer.

In some embodiments, a luster of the multi-component filament is higher than that of a multi-component filament that comprises the first polymer and the second polymer without the solid particles.

In some embodiments, the first polymer and the second polymer are different polymers. In some embodiments, the first polymer and the second polymer are the same polymer. In some embodiments, the first polymer and the second polymer may each be independently selected from a polyamide (for example, polyamide 6 or polyamide 6,6), a polyester (for example, polyethylene terephthalate or polytrimethylene terephthalate), or a polyolefin (for example, polyethylene or polypropylene).

According to a second aspect, a yarn is provided comprising a plurality of multi-component filaments as described herein.

According to a third aspect, a yarn is provided comprising at least one of a first filament and at least one of a second filament, wherein the first filament comprises a first polymer, and wherein the second filament comprises a second polymer and a plurality of solid particles dispersed within the second polymer.

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

BRIEF DESCRIPTION OF THE DRAWINGS

Example features and embodiments are disclosed in the accompanying drawings. However, the present disclosure is not limited to the precise arrangements shown, and the drawings are not necessarily drawn to scale.

FIG. 1 illustrates a perspective view of an elongated filament according to one embodiment.

FIG. 2 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 3 illustrates a cross-sectional view of a yarn according to one embodiment.

FIG. 4 illustrates a cross-sectional view of a filament according to one embodiment.

FIG. 5 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 6 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 7 illustrates a cross-sectional view of a filament according to one embodiment.

FIG. 8 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 9 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 10 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 11 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 12 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 13 illustrates a cross-sectional view of a filament according to another embodiment.

FIG. 14 illustrates a cross-sectional view of a filament according to another embodiment.

DETAILED DESCRIPTION

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

The term “comprising” and variations thereof as used herein is used synonymously with the term “including” and variations thereof and are open, non-limiting terms. Although the terms “comprising” and “including” have been used herein to describe various embodiments, the terms “consisting essentially of” and “consisting of” can be used in place of “comprising” and “including” to provide more specific embodiments of the invention and are also described. Other than in the examples, or where otherwise noted, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood at the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, to be construed in light of the number of significant digits and ordinary rounding approaches.

As used in the specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

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

Yarns and multi-component filaments having a plurality of solid particles dispersed throughout a portion of the filaments are described herein. Inclusion of solid particles through a portion of the filaments allows for differing certain properties in products formed from the filaments while maintaining desirable physical properties such as strength or abrasion resistance. For example, including translucent or transparent particles, such as glass flakes or mica, may differ the visual properties, such as providing an increased luster. And, in other implementations, opaque solid particles may be included through a portion of the filaments to create a different property for a product formed with the filament.

Thus according to a first aspect, a multi-component filament is provided comprising a first component comprising a first polymer and a second component comprising a second polymer and a plurality of solid particles dispersed within the second polymer, wherein the second component defines at least 50 percent of an external (or outermost) surface area of the multi-component filament. In some embodiments, the multi-component filament is a bicomponent filament.

A cross-sectional shape of the multi-component filaments described herein may be round or may have other shapes, such as octalobal, delta, sunburst (also known as sol), scalloped oval, trilobal, tetra-channel (also known as quatra-channel), kidney, scalloped ribbon, ribbon, starburst, semicircular, and the like. The cross-sectional shape refers to the shape of the filament as viewed in a plane that extends perpendicular to a central axis of the filament (e.g., an end view of the filament). The filaments may be solid, hollow, or multi-hollow (e.g., defining one or more axial voids therethrough).

FIGS. 1-2 and 4-14 illustrate cross-sectional views of bicomponent filaments having first and second polymers with different arrangements with respect to each other, in accordance with various embodiments of the first aspect. As shown, the second component comprises the second polymer and the plurality of solid particles dispersed therein and defines at least 50 percent of an external (or outermost) surface area of the bicomponent filament.

For example, FIG. 1 illustrates a bicomponent filament 120 that has a trilobal cross-sectional shape and includes a first component 122 and a second component 124. The first component 122 forms a core and is fully encapsulated by the second component 124. The first component 122 includes the first polymer, and the second component 124 includes the second polymer 124a and the plurality of solid particles 124b dispersed within the second polymer 124a. However, in other embodiments in accordance with the first aspect, the first component may not be fully encapsulated by the second component.

The bicomponent filament 130 shown in FIG. 2 also has a trilobal cross-sectional shape and includes first component 132 and second component 134. The second component 134 defines the trilobal shaped filament, and strands of the first component 132 are coupled to distal ends of each lobe of the second component 134. The first component 132 includes the first polymer, and the second component 134 includes the second polymer 134a and the plurality of solid particles 134b dispersed within the second polymer 134a. The strands of the first component 132 have a circular cross-sectional shape, but in other embodiments in accordance with the first aspect, the strands of the first component may have another cross-sectional shape, such as any of those described herein.

FIG. 4 illustrates another example of a core/sheath bicomponent filament 10. The first component 12 comprises a core and the second component 14 comprises a sheath that fully encapsulates the core. The first component 12 and the second component 14 both have circular cross-sectional shapes, and the first component 12 is centered within the volume of the second component 14. The first component 12 includes the first polymer, and the second component 14 includes the second polymer 14a and the plurality of solid particles 14b dispersed within the second polymer 14a.

The core/sheath bicomponent filament 20 in FIG. 5 is similar to the filament 10 in FIG. 4 in that the first component 22 is fully encapsulated by the second component 24 and components 12, 14 have circular cross-sectional shapes, but the first component 22 is not centered within the volume of the second component 24. The first component 22 includes the first polymer, and the second component 24 includes the second polymer 24a and the plurality of solid particles 24b dispersed within the second polymer 24a.

The filaments 10, 20 have a circular cross-sectional shape, but in other embodiments in accordance with the first aspect, the filaments may have other cross-sectional shapes, such as those described herein. In addition, these filaments 10, 20 have a circular shaped first component 12, 22 as viewed in the plane that extends perpendicular to the central axis of the filament 10, 20, but the first components in other embodiments in accordance with the first aspect may have other cross-sectional shapes, such as those described herein, and/or may define one or more voids therethrough.

As another example, in the bicomponent filament 30 shown in FIG. 6, the first component 32 and the second component 24 have a semi-circular shaped cross-section and are coupled together along flat surfaces of each component 32, 34 along a plane that includes the central axis of the filament. An external surface of the filament 30 has a circular cross-sectional shape. The first component 32 includes the first polymer, and the second component 34 includes the second polymer 34a and the plurality of solid particles 34b dispersed within the second polymer 34a. In other embodiments in accordance with the first aspect, the volume of the second component 34 in the filament may be increased relative to the first component 32 such that the plane along which the components are coupled is spaced apart from the plane that includes the central axis.

As another example, a cross-sectional shape of the external surface of the bicomponent filament 40 shown in FIG. 7 follows the external contour of the number 8. The first component 42 and the second component 44 each have a partial circular cross-sectional shape, and the components 42, 44 are coupled together along a plane that includes a chord of each cross-section, wherein the chord has a length that is less than a diameter of each component 42, 44. The plane in which the components 42, 44 are coupled includes a central axis of the filament 40. The first component 42 includes the first polymer, and the second component 44 includes the second polymer 44a and the plurality of solid particles 44b dispersed within the second polymer 44a. In other embodiments in accordance with the first aspect, the plane in which the components 42, 44 are coupled may be spaced apart from the central axis of the filament.

The bicomponent filament 50 shown in FIG. 8 is similar to the filament 30 shown in FIG. 6 but defines a circular shaped axial void 56 that is centered within the filament 50, as viewed in the plane that extends perpendicular to a central axis of the filament 50. The first component 52 includes the first polymer, and the second component 54 includes the second polymer 54a and the plurality of solid particles 54b dispersed within the second polymer 54a.

The bicomponent filament 60 shown in FIG. 9 is similar to the bicomponent filament 50 in FIG. 8, but the circular-shaped void 66 is not centered within the filament 60. The first component 62 includes the first polymer, and the second component 64 includes the second polymer 64a and the plurality of solid particles 64b dispersed within the second polymer 64a.

The bicomponent filament 70 shown in FIG. 10 has a circular cross-sectional shape and defines an axial void 76 that is centered in the filament. The first component 72 and the second component 74 are arranged circumferentially around the central axis of the filament in alternating radial segments. For example, the filament 70 has sixteen radial segments, wherein the first component 72 and the second component 74 are alternately arranged around the central axis and void 76 of the filament 70. The first component 72 includes the first polymer, and the second component 74 includes the second polymer 74a and the plurality of solid particles 74b dispersed within the second polymer 74a. In other embodiments in accordance with the first aspect, the filament can have four or more alternating segments of the first and second components and no axial voids or more than one axial voids. For example, the bicomponent filament 80 in FIG. 11 shows an example of a bicomponent filament 80 having no axial voids but includes the circumferential arrangement of the first component 82 and the second component 84 in alternating radial segments. The first component 82 includes the first polymer, and the second component 84 includes the second polymer 84a and the plurality of solid particles 84b dispersed within the second polymer 84a. In addition, the angle of each segment in the filaments 70, 80 are the same, but in other embodiments in accordance with the first aspect, the angle of each segment may be varied relative to the other segments to increase the amount of surface area on the exterior surface of the filament.

The bicomponent filament 90 shown in FIG. 12 has a circular cross-sectional shape and includes alternating chord segments of the first component 92 and the second component 94. For example, the filament 90 has seven segments, but in other embodiments in accordance with the first aspect, the filament may have two or more alternating chord segments. The segments of filament 90 may have equal widths (as measured along a diameter of the filament 90) or the segments may have unequal widths to allow one of the components 92, 94 to occupy a greater surface area of the exterior surface of the filament 90. The first component 92 includes the first polymer, and the second component 94 includes the second polymer 94a and the plurality of solid particles 94b dispersed within the second polymer 94a.

The bicomponent filament 100 shown in FIG. 13 has a circular cross-sectional shape and includes a first component 102 and a second component 104. The first component 102 is mostly encapsulated by the second component 104 but a portion of the first component 102 extends to the exterior surface of the filament 100. The first component 102 includes the first polymer, and the second component 104 includes the second polymer 104a and the plurality of solid particles 104b dispersed within the second polymer 104a.

The bicomponent filament 110 shown in FIG. 14 has a circular cross-sectional shape and includes first component 112 and second component 114. The first component 112 comprises multiple strands extending axially through the second component 114, and the second component 114 encapsulates the first component 112 strands. Some of the strands of the first component 112 are circumferentially arranged in rings 112a-e, and the rings 112a-e are radially spaced from each other and centered with respect to a central strand 112e, which extends along the central axis of the filament 110. The first component 112 includes the first polymer, and the second component 114 includes the second polymer 114a and the plurality of solid particles 114b dispersed within the second polymer 114a.

In other embodiments according to the first aspect, the filaments may include more than two components and/or have any cross-sectional shape, including any of the shapes described herein.

A plurality of any of the multi-component filaments described herein may be combined into a yarn according to the second aspect. For example, a plurality of any of the bicomponent filaments described herein may be combined into a yarn.

FIG. 3 shows a cross-section of filaments that are combined into a yarn 140 according to one embodiment in accordance with the third aspect. The yarn 140 includes a first set of filaments 142 comprising (e.g., consisting of) the first polymer and a second set of filaments 144 comprising (e.g., consisting of) the second polymer having solid particles dispersed therein. Each filament has a tri-lobal shaped cross-sectional shape, but in other embodiments, one or more of the filaments may have other cross-sectional shapes, such as those described herein. The sets of filaments 142, 144 are combined together to form the yarn 140. The filaments from the second set of filaments define at least fifty percent of the external surface area of the yarn 140.

In addition, in other embodiments in accordance with the third aspect, the filaments in each set may be single component or have two or more components. And, in other embodiments in accordance with the third aspect, the cross-sectional shape of the first filaments and the second filaments can be the same or different, and the cross-sectional shape of filaments in each of set of filaments can be the same or different.

In some embodiments according to any of the first, second, or third aspect, the first polymer and the second polymer are the same, and in other embodiments, the first polymer and the second polymer are different.

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

Any of the embodiments described below in the specification can be applied to any of the first through third aspects.

In some embodiments, the first polymer and the second polymer may independently comprise a polymer selected from a polyamide, a polyester, or a polyolefin. In some embodiments, the first polymer and the second polymer comprise the same polymer. In some embodiments, the first polymer comprises a polyamide and the second polymer comprises a polyester. In some embodiments, the first polymer comprises a polyamide and the second polymer comprises a polyolefin. In some embodiments, the first polymer comprises a polyester and the second polymer comprises a polyamide. In some embodiments, the first polymer comprises a polyester and the second polymer comprises a polyolefin. In some embodiments, the first polymer comprises a polyolefin and the second polymer comprises a polyamide. In some embodiments, the first polymer comprises a polyolefin and the second polymer comprises a polyester. In some embodiments, the first polymer and the second polymer each independently comprise a polyamide, either the same polyamide or two different polyamides. In some embodiments, the first polymer and the second polymer each independently comprise a polyester, either the same polyester or two different polyesters. In some embodiments, the first polymer and the second polymer each independently comprise a polyolefin, either the same polyolefin or two different polyolefins.

A polyamide is defined as a synthetic linear polymer whose repeating unit contains amide functional groups, wherein these amide functional groups are integral members of the linear polymer chain.

In some embodiments, the polyamide may have been formed by condensation polymerization of a dicarboxylic acid and a diamine Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-napthalene dicarboxylic acid, 3,4′-diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-naphthalenedicarboxylic acid, phthalic acid, 4,4′-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediactic acid, fumaric acid, and maleic acid. Representative examples of such diamines include ethylene diamine, tetramethylene diamine, hexamethylene diamine, 1,9-nonanediamine, 2-methyl pentamethylene diamine, trimethyl hexamethylene diamine (TMD), m-xylylene diamine (MXD), and 1,5-pentanediamine.

In some embodiments, the polyamide may have been formed by condensation polymerization of an amino acid (such as 11-aminoundecanoic acid) or ring-opening polymerization of a lactam (such as caprolactam or w-aminolauric acid).

Representative examples of polyamides as may be used in the present disclosure include: aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 6I, polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide 12T, polyamide PACM12, polyamide TMDT, polyamide 611, and polyamide 1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, and polyamide L6T/6I; and aramid polymers.

A polyester is defined as a synthetic linear polymer whose repeating units contain ester functional groups, wherein these ester functional groups are integral members of the linear polymer chain.

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

Representative examples of polyesters include poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(butylene terephthalate) (PBT), poly(ethylene isophthalate), poly(octamethylene terephthalate), poly(decamethylene terephthalate), poly(pentamethylene isophthalate), poly(butylene isophthalate), poly(hexamethylene isophthalate), poly(hexamethylene adipate), poly(pentamethylene adipate), poly(pentamethylene sebacate), poly(hexamethylene sebacate), poly(1,4-cyclohexylene terephthalate), poly (1,4-cyclohexylene sebacate), poly(ethylene terephthalate-co-sebacate), and poly(ethylene-co-tetramethylene terephthalate).

A polyolefin comprises a polymer formed from a simple olefin as a monomer. Representative examples of polyolefins which may be used in the present disclosure include, but are not limited to, polyethylene or polypropylene.

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

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

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

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

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

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

In one aspect, a plurality of solid particles are dispersed within the second polymer. In some embodiments, the first component may further comprise a plurality of solid particles dispersed in the first polymer, the plurality of solid particles having a concentration by volume in the first polymer that is less than a concentration by volume of the particles of the second polymer. In some embodiments, the solid particles are evenly dispersed in the first polymer. In some embodiments, the plurality of solid particles have a concentration volume in the first polymer that is 10% less, 20% less, 30% less, 40% less, 50% less, 60% less, 70% less, 80% less, or 90% less than the concentration by volume of the particles in the second polymer. In other embodiments, the first component does not comprise solid particles dispersed in the first polymer.

In some embodiments, the solid particles may have an average particle diameter ranging from 5 microns to 35 microns, for example from 5 micron to 30 microns, from 5 microns to 25 microns, from 5 microns to 20 microns, from 5 microns to 15 microns, from 5 microns to 10 microns, from 10 microns to 35 microns, from 10 microns to 30 microns, from 10 microns to 25 microns, from 10 microns to 20 microns, from 10 microns to 15 microns, from 15 microns to 35 microns, from 15 microns to 30 microns, from 15 microns to 25 microns, from 15 microns to 20 microns, from 20 microns to 35 microns, from 20 microns to 30 microns, from 20 microns to 25 microns, from 25 microns to 35 microns, from 25 microns to 30 microns, or from 30 microns to 35 microns. In some embodiments, the solid particles may have an average particle diameter of 5 microns, 6 microns, 7 microns, 8 microns, 9 microns, 10 microns, 11 microns, 12 microns, 13 microns, 14 microns, 15 microns, 16 microns, 17 microns, 18, microns, 19 microns, 20 microns, 21 microns, 22 microns, 23 microns, 24 microns, 25 microns, 26 microns, 27 microns, 28 microns, 29 microns, 30 microns, 31 microns, 32 microns, 33 microns, 34 microns, or 35 microns.

In some embodiments, the solid particles may comprise glass flakes. In some embodiments, the glass flakes may comprise E-glass, C-glass, E-CR-glass, or combinations thereof. “E-glass” refers to alumino-borosilicate glass having less than 1% alkali oxides by weight. “C-glass” refers to alkali-lime glass with a high boron oxide content. “E-CR-glass” refers to alumino-lime silicate glass with less than 1% alkali oxides by weight.

In some embodiments, the glass flakes may have an average particle diameter ranging from 5 microns to 35 microns, for example from 5 micron to 30 microns, from 5 microns to 25 microns, from 5 microns to 20 microns, from 5 microns to 15 microns, from 5 microns to 10 microns, from 10 microns to 35 microns, from 10 microns to 30 microns, from 10 microns to 25 microns, from 10 microns to 20 microns, from 10 microns to 15 microns, from 15 microns to 35 microns, from 15 microns to 30 microns, from 15 microns to 25 microns, from 15 microns to 20 microns, from 20 microns to 35 microns, from 20 microns to 30 microns, from 20 microns to 25 microns, from 25 microns to 35 microns, from 25 microns to 30 microns, or from 30 microns to 35 microns. In some embodiments, the glass flakes have an average particle diameter of 5 microns, 6 microns, 7 microns, 8 microns, 9 microns, 10 microns, 11 microns, 12 microns, 13 microns, 14 microns, 15 microns, 16 microns, 17 microns, 18, microns, 19 microns, 20 microns, 21 microns, 22 microns, 23 microns, 24 microns, 25 microns, 26 microns, 27 microns, 28 microns, 29 microns, 30 microns, 31 microns, 32 microns, 33 microns, 34 microns, or 35 microns. In some embodiments, the glass flakes may have an average diameter ranging from 27 microns to 32 microns. In some embodiments, the glass flakes may have an average diameter ranging from 20 microns to 50 microns. In some embodiments, the glass flakes may have an average diameter ranging from 8 microns to 12 microns.

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

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

In some embodiments, the glass flakes comprise C-glass flakes having an average diameter ranging from 20 microns to 50 microns and an average thickness ranging from 3 microns to 7 microns.

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

In some embodiments, the solid particles may comprise mica particles. Typically, the mica particles comprise ground mica, for example wet-ground mica which maintains the brilliance of the cleavage faces of the sheet material. The mica particles as used in the present disclosure may comprise muscovite, paragonite, biotite, lepidolite, phlogopite, zinnwaldite, clintonite, hydro-muscovite, illite, phengite, or sericite.

In some embodiments, the solid particles, for example glass flakes or mica particles, may be surface treated with a coating prior to being dispersed within the second polymer. This coating can reduce the abrasiveness of the solid particles. In some embodiments, the coating comprises a silane coating. Representative examples of silane coatings which may be used in the present disclosure include, but are not limited to, 3-aminopropyltriethoxysilane, vinyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, or 3-methacryloxypropyltrimethoxysilane.

In some embodiments, the solid particles, for example glass flakes or mica particles, may have a concentration of at least 10% by volume within the second polymer. In some embodiments, the solid particles, for example glass flakes, may have a concentration of 10%, 15%, 20%, 25%, 30%, 35% or 40% by volume within the second polymer.

In some embodiments, the filaments may further comprise one or more additives including, but limited to: flame retardant additives, for example decabromodiphenyl ether and triarylphosphates such as triphenyl phosphate; reinforcing agents; thermal stabilizers, for example thermal conductivity improvers such as zinc oxide and titanium oxide; ultraviolet light stabilizers such as resorcinol monobenzoates, phenyl salicylate and 2-hydroxybenzophenones; hindered amine stabilizers such as benzotriazole, benzophenone, oxalanilide, and cerium oxide; impact modifiers; flow enhancing additives; ionomers; liquid crystal polymers; fluoropolymers; olefins including cyclic olefins; polyamides; ethylene vinyl acetate copolymers; stabilizing agents such as ortho-phosphoric acid, triphenylphosphate, and triethylphosphino acetate; delustering agents such as titanium oxide; carriers such as o-phenylphenol, p-phenylphenol, o-dichlorobenzene, trichlorobenzene, monochlorobenzene, biphenyl, methyl salicylate, butyl benzoate, benzyl benzoate, benzoic acid, benzalacetone, and methyl cinnamate; leveling agents such as bishydroxymethyloxazoline, diaryl ethers, ditolyl ether, sodium di-naphthylmethane-B,B-disulfonate, ammonium dodecylbenzene sulfonate, sodium tetrapropylbenzene sulfonate, homopolymers or oligomers of N-vinylpyrrolidone and poly(tetrahydrofuran); and porosity additives such as metal oxalate complexes, organic sulfonate salts, jade powder, and zeolite powder.

In some embodiments according to any of the first through third aspects, the multi-component filament or yarn may have a luster greater than a multi-component filament or yarn that comprises the first polymer and the second polymer without the solid particles. “Luster” refers to the brightness or sheen of the filament and is associated with the degree of light that is reflected from the surface of the filament or the degree of gloss or sheen that the filament possesses. The inherent chemical and physical structure and shape of the fiber can affect the relative luster of the filament. Synthetic filaments may be characterized by a variety of luster classifications, such as bright, semi-bright, semi-dull, and mid-dull, and the luster can be influenced by heat setting, dyeing, or finishing of any fibers formed from the filaments. Luster results from the way light is reflected from the surface. The more lustrous a fiber, the more evenly it reflects incident light.

Luster may be measured by any number of commercially available lustermeters as would be known to one skilled in the art. With such instruments, luster is measured as the contrast and ratio between the specular reflectance and the diffuse reflectance. The specular reflectance factor can be expressed as R_S (45°/45° gloss), and the diffuse reflectance factor expressed as R_D (45°/0° diffuse reflectance). Reflectance indicates the degree of diffuse light at 90 degrees to the filament surface with the incident light at 45 degrees to the filament surface. The angle between the light source and detector is 45 degrees. Gloss designates the degree of light measured at 45 degrees to the filament surface with the incident light again at 45 degrees to the filament surface. The angle between the light source and the detector is 90 degrees. Luster is calculated from the ratio of Gloss to Reflectance as follows: Luster=100−(4.5)=(R_D/R_S).

Also provided are manufactured products, such as textiles including carpets, produced using a filament or yarn of any one of the first through third aspects described herein.

A number of embodiments of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.

Claims

1.-77. (canceled)

78. A multi-component filament comprising:

a first component comprising a first polymer; and

a second component comprising a second polymer and a plurality of transparent or translucent solid particles evenly dispersed within the second polymer;

wherein the second component defines at least 50 percent of an external surface area of the multi-component filament.

79. The multi-component filament of claim 78, wherein the first component comprises a plurality of transparent or translucent solid particles dispersed in the first polymer, wherein the plurality of solid particles have a concentration by volume in the first polymer that is less than a concentration by volume of the solid particles in the second polymer.

80. The multi-component filament of claim 79, wherein the first polymer consists of a polymer selected from the group of a polyamide, a polyester, and a polyolefin.

81. The multi-component filament of claim 80, wherein the second polymer consists of a polymer selected from the group of a polyamide, a polyester, and a polyolefin.

82. The multi-component filament of claim 81, wherein the solid particles comprise an average particle diameter ranging from 5 microns to 35 microns and an average thickness ranging from 0.5 microns to 8 microns.

83. The multi-component filament of claim 82, wherein the solid particles are selected from a group consisting of glass and mica.

84. The multi-component filament of claim 83, wherein the solid particles have been treated with a silane coating comprising a silate coupling reagent selected from the group consisting of 3-aminopropyltriethoxysilane, vinyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, and 3-methacryloxypropyltrimethoxysilane.

85. The multi-component filament of claim 84, wherein the solid particles have a concentration of at least 10% by volume within the second polymer.

86. The multi-component filament of claim 85, wherein a cross-sectional shape of the multi-component filament is configured to be selected from a group consisting of round, octalobal, delta, sunburst, scalloped oval, trilobal, tetra-channel, kidney, scalloped ribbon, ribbon, starburst, and semicircular.

87. The multi-component filament of claim 86, wherein the first polymer and the second polymer are the same.

88. A yarn comprising at least one of a first filament and at least one of a second filament;

wherein the first filament comprises a first polymer; and

wherein the second filament comprises a second polymer and a plurality of solid particles evenly dispersed within the second polymer.

89. The yarn of claim 88, wherein the first polymer consists of a polymer selected from the group of a polyamide, a polyester, and a polyolefin.

90. The yarn of claim 89, wherein the second polymer consists of a polymer selected from the group of a polyamide, a polyester, and a polyolefin.

91. The yarn of claim 90, wherein the solid particles are transparent or translucent.

92. The yarn of claim 91, wherein the at least one first filament comprises a plurality of first filaments, and the at least one second filament comprises a plurality of second filaments, and wherein the plurality of second filaments define at least 50 percent of an external surface area of the yarn.

93. The yarn of claim 92, wherein the solid particles comprise wet-ground mica particles selected from the group consisting of muscovite, paragonite, biotite, lepidolite, phlogopite, zinnwaldite, clintonite, hydro-muscovite, illite, phengite, or sericite.

94. The yarn of claim 92, wherein the solid particles comprise glass flakes having an average particle diameter ranging from 5 microns to 35 microns, an average thickness ranging from microns to 8 microns, are comprised of E-glass, C-glass, E-CR-glass, or combinations thereof, and have been coated with a silane coupling reagent selected from the group consisting of 3-aminopropyltriethoxysilane, vinyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, and 3-methacryloxypropyltrimethoxysilane.

95. The yarn of claim 94, wherein the glass flakes have a concentration of at least 10% by volume within the second polymer.

96. The yarn of claim 95, wherein the first polymer is the same as the second polymer.

97. A multi-component filament comprising: wherein the first and second polymers are each selected from the group consisting of a polyamide, a polyester, and a polyolefin; wherein the solid particles comprise glass flakes with an average particle diameter ranging from 5 microns to 35 microns and an average thickness ranging from 0.5 microns to 8 microns, and have been treated with a silane coupling reagent selected from the group consisting of 3-aminopropyltriethoxysilane, vinyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, and 3-methacryloxypropyltrimethoxysilane; and wherein the glass flakes have a concentration of at least 10% by volume within the second polymer.

a first component comprising a first polymer with a plurality of solid particles evenly dispersed within the first polymer; and

a second component comprising a second polymer and a plurality of solid particles evenly dispersed within the second polymer;

wherein the second component defines at least 50 percent of an external surface area of the multi-component filament;