SYNTHETIC FIBER CONTAINING AEROGEL AND POLYMER MATERIAL, AND METHODS OF MAKING AND ARTICLES COMPRISING THE SAME
The invention provides a synthetic fiber that includes: 0.1 to 15 wt % aerogel particles having an average diameter of 0.3 to 20 μm; and 85 to 99.9 wt % polymer material, the synthetic fiber having a denier of 0.1 to 9.0. Also provided are articles that include the synthetic fiber, and methods of making the synthetic fiber.
1 . A synthetic fiber comprising:
0.1 to 15 wt % aerogel particles, said aerogel particles having an average diameter of 0.3 to 20 μm; and
85 to 99.9 wt % polymer material,
wherein the synthetic fiber has a denier of 0.1 to 9.0.
2 . The synthetic fiber according to claim 1 , wherein the aerogel particles comprise inorganic aerogel.
3 . The synthetic fiber according to claim 2 , wherein the aerogel particles comprise silica aerogel.
4 . The synthetic fiber according to claim 1 , wherein the synthetic fiber is siliconized.
5 . The synthetic fiber according to claim 1 , comprising 0.5 to 10 wt % of the aerogel particles.
6 . The synthetic fiber according to claim 5 , comprising 1 to 3 wt % of the aerogel particles.
7 . The synthetic fiber according to claim 1 , wherein the aerogel particles have an average diameter of 2 to 5 μm.
8 . The synthetic fiber according to claim 1 , wherein the aerogel particles are homogenously dispersed within the polymer material.
9 . The synthetic fiber according to claim 1 , wherein the polymer material comprises nylon, polyester, acrylic or polyolefin polymer, or a combination thereof
10 . The synthetic fiber according to claim 9 , wherein the polymer material comprises polyester.
11 . The synthetic fiber according to claim 10 , wherein the polyester is polyethylene terephthalate.
12 . The synthetic fiber according to claim 1 , having a denier of 0.7 to 2.0.
13 . The synthetic fiber according to claim 1 , wherein the fiber is a staple fiber having a length of 5 to 120 mm.
14 . (canceled)
15 . The synthetic fiber according to claim 13 , wherein the fiber is crimped.
16 . The synthetic fiber according to claim 1 , wherein the fiber is a filament.
17 . Batting, insulation material, or yarn comprising the synthetic fiber according to claim 1 .
18 . (canceled)
19 . (canceled)
20 . An article comprising the synthetic fiber according to claim 1 .
21 . The article according to claim 20 , wherein said article is selected from the group consisting of an outerwear product, footwear, clothing, a sleeping bag, and bedding.
22 . A method of making the synthetic fiber according to claim 1 , said method comprising:
mixing the aerogel particles and the polymer material, thereby forming an aerogel/polymer mixture;
extruding the aerogel/polymer mixture; and
optionally performing one or more additional processing steps, thereby forming the synthetic fiber.
23 . (canceled)
24 . The method according to claim 22 , where said extruding the aerogel/polymer mixture comprises subjecting a dry aerogel/polymer mixture to a melt extrusion process, thereby forming an aerogel/polymer pellet.
25 . (canceled)
26 . (canceled)