Xerographic method for coating a material with solid particles
The present invention relates to methods for imprinting solid particles onto materials that enhance the performance characteristics, such as the odor adsorption capacity, of the material. The present invention uses a xerographic imprinting method to apply a toner formulation to the material. The toner formulation typically includes solid particles (e.g., activated carbon), binding agents, and additives. Using this method, a specific pattern can be imprinted onto the material. The present invention can also use a Gravure method to imprint performance enhancing solid particles onto a material. This method advantageously provides precise control over the volume of mixture (e.g., solid particles and binding agent) impressed onto the material. In addition, this method can imprint specific patterns of mixture onto the material.
1. A method for producing a performance enhanced material, comprising:
xerographically transferring a toner formulation to a drum assembly, the toner formulation comprising:
activated carbon having an adsorptive capacity; and
a binding agent;
imprinting the toner formulation onto the material via the drum assembly; and
fusing the activated carbon to the material with the binding agent such that the activated carbon bound thereto imparts its adsorptive capacity to the material.
2. The method according to claim 1 , wherein said activated carbon imparts properties selected from the group consisting of odor-adsorption, moisture management, ultraviolet light protection, thermal insulation, thermal regulation, antiviral protection, antibacterial protection, antifungal protection, antimicrobial protection, fire protection, chemical agent protection, infrared light protection, and any combination thereof.
3. The method according to claim 1 , further comprising preparing the toner formulation by:
milling the activated carbon and the binding agent; and
extruding the toner formulation from the milled activated carbon and binding agent.
4. The method according to claim 1 , wherein the transferring comprises electrostatically transferring the toner formulation to the drum assembly.
5. The method according to claim 1 , wherein the transferring comprises magnetically transferring the toner formulation to the drum assembly.
6. The method according to claim 1 , wherein the transferring comprises applying the toner formulation in a pattern onto the drum assembly.
7. The method according to claim 6 , wherein the pattern is imprinted onto the material.
8. The method according to claim 1 , wherein the fusing comprises subjecting the material and the impressed toner formulation to an elevated temperature that causes the binding agent to attach the activated carbon to the material.
9. The method according to claim 1 , wherein the binding agent is selected from the group consisting of natural rubber latex, NEOPRENE, styrene butadiene, acrylic/acrylonitrile copolymer, modified n-butyl acrylonitrile copolymer, acrylonitrile polyvinyl acetate, polyacrylate, acrylonitrile butadiene, acrylic methyl methacrylate, self cross-linking copolymers of vinyl acetate, self cross-linking copolymers of ethylene, polystyrenes, polyesters, polyvinyl alcohol, polyvinyl acetate, vinyl chloride copolymers, melamine-formaldehyde resins, starches, carboxymethyl cellulose, methyl cellulose, sodium silicate, and siloxanes, including functionalized saloxanes, and any combination thereof.
10. The method of claim 1 , wherein the toner comprises a plurality of additives selected from the group consisting of charge control additives, electrostatic charge control additives, magnetic charge control additives, silicon control additives, coloring additives, and any combination thereof.
11. A woven material having the activated carbon embedded therein according to the method of claim 1 .
12. A non-woven material having the activated carbon embedded therein according to the method of claim 1 .
13. A yarn having the activated carbon embedded therein according to the method of claim 1 .
14. A foam having the activated carbon embedded therein according to the method of claim 1 .
15. A knitted material having the activated carbon embedded therein according to the method of claim 1 .