REDUCED DENSITY SYNTHETIC FIBER UTILIZING HOLLOW MICROCAPSULES
The invention provides a synthetic fiber that includes: 0.4 to 30 wt % hollow microcapsules having an average diameter of 4 to 30 μm; and 70 to 99.6 wt % polymer material, wherein the synthetic fiber has a denier of 0.1 to 11.0. Also provided are yarn, insulation material, and articles that include the synthetic fiber, and methods of making the same.
1 . A synthetic fiber comprising:
0.4 to 30 wt % hollow microcapsules having an average diameter of 4 to 30 μm; and
70 to 99.6 wt % polymer material,
wherein the synthetic fiber has a denier of 0.1 to 11.0.
2 . The synthetic fiber according to claim 1 , wherein the hollow microcapsules are microspheres.
3 . The synthetic fiber according to claim 1 , wherein the microcapsules are glass microspheres.
4 . The synthetic fiber according to claim 1 , wherein the microcapsules are soda-lime borosilicate glass microspheres.
5 . The synthetic fiber according to claim 1 , wherein the synthetic fiber is siliconized.
6 . The synthetic fiber according to claim 1 , comprising 7 to 15 wt % of the hollow microcapsules.
7 . The synthetic fiber according to claim 1 , wherein the hollow microcapsules have an average diameter of 5 to 20 μm.
8 . The synthetic fiber according to claim 7 , wherein the hollow microcapsules have an average diameter of 4 to 12 μm.
9 . The synthetic fiber according to claim 1 , wherein the hollow microcapsules are homogenously dispersed within the polymer material.
10 . The synthetic fiber according to claim 1 , wherein the polymer material comprises nylon, polyester, polypropylene, acrylic or polyolefin polymer, or a combination thereof.
11 . The synthetic fiber according to claim 10 , wherein the polymer material comprises polyester.
12 . The synthetic fiber according to claim 11 , wherein the polyester is polyethylene terephthalate, polybutylene terephthalate, or a combination thereof.
13 . (canceled)
14 . The synthetic fiber according to claim 1 , having a denier of 0.7 to 6.0.
15 . The synthetic fiber according to claim 1 , wherein the fiber is a staple fiber having a length of 5 to 120 mm.
16 . (canceled)
17 . The synthetic fiber according to claim 16 , wherein the fiber is crimped.
18 . (canceled)
19 . The synthetic fiber according to claim 1 , additionally comprising aerogel particles.
20 . Insulation material comprising the synthetic fiber according to claim 1 .
21 . Insulation material according to claim 20 , wherein said insulation material is blowable insulation or filling material, comprising:
a plurality of discrete, longitudinally elongated floccules each formed of a plurality of the synthetic fibers, the floccules including a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion.
22 . An article comprising the synthetic fiber according to claim 1 .
23 . A method of making the synthetic fiber according to claim 1 , said method comprising:
mixing the hollow microcapsules and the polymer material, thereby forming a microcapsule/polymer mixture;
extruding the microcapsule/polymer mixture; and
optionally performing one or more additional processing steps,
thereby forming the synthetic fiber.