Use of permanent coatings on fibers, fiber components and components thereof

Abstract

A fiber bundle and a method of making a fiber bundle are provided, the fiber bundle comprising at least one filament, where the filament comprises a surface having a gap in a surface. A cured thermoplastic polymer is on the surface, where the cured thermoplastic polymer includes a coating material, and the cured thermoplastic polymer and the coating material extend into a gap.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to pending U.S. patent application Ser. No. 17 / 816,405, filed on July 30, 2022, which is incorporated herein by reference. Technical Field

[0003] The present invention relates to the purpose and application of a wide range of permanent and permeable coatings of carbon, glass, polymer, cellulose, protein and other fiber components and filaments to enhance their aesthetic appearance through pigments, their physical properties through altered strength or elongation, their medical functions through antimicrobial materials or their environmental sustainability. Background Art

[0004] The application of coatings to fibers or filaments and products containing them is an important economic activity worldwide. Fiber assemblies or superstructures are made from fibrous materials or substrates, ranging from cotton fibers to interconnected bundles of carbon nanotubes. Traditionally, fiber assemblies and filaments are colored using a combination of large amounts of water, chemical dyes, heat, and high pressure. These processes result in little penetration of the color to the surface of the fiber assembly or filament, which can be removed by subsequent use, chemical bleaching, and light of various spectra.

[0005] Chemical coatings are applied to fiber components and filaments to improve aesthetics, physical properties or medical function. In commonly used techniques, chemical coatings are applied to the surface of the fiber or fiber bundle and then cured by heat or light. These coatings are not durable and typically wear or flake off quickly through planned use or exposure to sunlight or other light sources.

[0006] In addition to the lack of robustness, prior art methods for coating fiber components and filaments suffer from the use of hundreds to thousands of liters of clean water for each kilogram of material processed, as well as the addition of dozens of hazardous chemicals in each process to apply the coating, much of which is discarded as lightly treated or untreated wastewater and other materials.

[0007] In-depth research has found that the poor adhesion of colorants or pigments to fiber components and filaments is the main reason for their lack of robustness. This article describes an advanced material method in which the robustness of the coating is significantly enhanced. In addition to providing enhanced robustness, the present invention can significantly reduce the use of materials, which is beneficial both economically and environmentally. Summary of the invention

[0008] One aspect of the present invention is to provide an improved method for providing permeable and durable coatings to superstructures, fiber assemblies, and filaments or fibers (collectively referred to as fiber bundles) using materials that can produce aesthetic changes (such as color and / or texture) or performance-oriented changes (such as anti-biodegradable materials or improved environmental standards).

[0009] Another aspect of the present invention is the use of corona discharge plasma to restructure the fiber bundle to ensure that the surface area has the appropriate adhesion and create gaps to permanently fix the permeable and durable coating to the fiber bundle.

[0010] Another aspect of the present invention is to expose the fiber bundle to an ionic surfactant, anionic surfactant or acidic surfactant solution to further enhance surface adhesion and expand the gap.Sufficient energy is required when applying the thermoplastic polymer to ensure that the physical parameters are maintained during the application of the coating material.

[0011] Another aspect of the invention is the use of a linear manufacturing system with high temperature and high humidity to ensure electrical and chemical modification of the fiber bundle; preferably in the form of a superstructure, filament assembly, filament or fiber that is permanent and resistant to future oxidation, heat or other damage.

[0012] Another aspect of the invention is to feed the fiber bundle into an air diffusion device which applies a chemical mixture of coating materials to the top of the fiber bundle at a specific pressure. The air diffusion device provides a chemical mixture of thermoplastic polymer and coating materials in a particle size sufficient to promote the realization of specific properties, such as imparting pigment, antimicrobial properties, temperature resistance, strength enhancement, lubricity, luminosity, reflectivity or environmental properties by initiating a cross-linking reaction by forming physical connections during processing or moderate heating to produce covalent bonds that are not sensitive to hydrolytic agents.

[0013] Another aspect of the invention is that all fluids, surfactant solutions, water, pigments and other chemicals are used until they are exhausted at each process stage, so minimal, if any, waste is generated and no gases or fluids are released into the environment for treatment or disposal.

[0014] As will be appreciated, these and other embodiments provide a fiber bundle comprising at least one filament, wherein the filament comprises a surface having interstices thereon, a solidified thermoplastic polymer on the surface, wherein the solidified thermoplastic polymer comprises a coating material, and the solidified thermoplastic polymer and the coating material extend into the interstices.

[0015] Another embodiment provides a method of forming a coated fiber bundle, comprising:

[0016] subjecting at least one fiber bundle to a plasma discharge to form a treated fiber bundle including gaps;

[0017] treating the treated fiber bundle with a surfactant activated by ultrasonic energy to form a wetted fiber bundle;

[0018] applying a thermoplastic polymer and a coating material to the wet fiber bundle to form an impregnated fiber bundle, wherein the thermoplastic polymer and the coating material impregnate the interstices; and

[0019] Curing of thermoplastic polymers. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic top view of an embodiment of the present invention.

[0021] Figure 2 is a schematic side view of an embodiment of the present invention.

[0022] Figure 3 is a schematic side view of an embodiment of the present invention.

[0023] Figure 4 is a schematic side view of an embodiment of the present invention.

[0024] Figure 5 is a schematic side view of an embodiment of the present invention.

[0025] Figure 6 is a schematic side view of an embodiment of the present invention.

[0026] Figure 7 is a schematic cross-sectional view of an embodiment of the present invention.

[0027] Figure 8 is a schematic cross-sectional view of an embodiment of the present invention, and Fig. 9 Schematic diagram of an embodiment of the present invention. DETAILED DESCRIPTION

[0028] The present invention relates to a method of improving the coating of fiber bundles; preferably, in the form of superstructures, fiber assemblies, filaments or fibers, to form improved fiber bundles. More specifically, the present invention relates to a method of forming interstices in a fiber bundle, followed by the use of a surfactant, an activated thermoplastic polymer and a coating material, and optionally fixing, to provide a fiber bundle with improved coating robustness.

[0029] As used herein, "filament" or "fiber" are used interchangeably and refer to a natural or synthetic material that is significantly longer than it is wide, usually in the form of extremely thin threads.

[0030] As used herein, a "fiber assembly" is a bundle of fibers or filaments bundled together in parallel, twisted, or entangled to form a single strand.

[0031] As used herein, a "superstructure" comprises a plurality of fiber assemblies together to form a shaped article.

[0032] As used herein, "planar" refers to the horizontal presentation of one, dozens, hundreds, or thousands of superstructure components on a horizontal plane, where the superstructures are placed side by side and slightly touching each other, with the contact distance measured in nanometers or micrometers.

[0033] As used herein, "corona discharge plasma" is a high voltage corona discharge plasma that has the effect of modifying the surface to improve adhesion, thereby allowing permanent coating in a subsequent step.

[0034] As used herein, "surfactant" refers to a compound that reduces the surface tension between two liquids, between a gas and a liquid, or between a liquid and a solid. Depending on the coating surface, the surfactant can be a cationic surfactant, an anionic surfactant, and an acidic surfactant.

[0035] As used herein, "fiber bundle" is used for clarity and refers to a superstructure, fiber assembly, filament or fiber, or a collection thereof.

[0036] As used herein, "thermoplastic polymers" are materials that become flexible or shaped at a specific elevated temperature and solidify upon cooling. Particularly preferred thermoplastic polymers include polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), nylon (PA), polystyrene (PS), polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), polyolefin elastomer (POE), polymethyl methacrylate (PMMA), poly(ethyl acrylate) (PEA), poly(butyl acrylate) (PBA), poly(2-ethylhexyl acrylate) (PEHA), poly(acrylic acid) (PAA), and copolymers of acrylic acid and other monomers (such as styrene, acrylonitrile and vinyl acetate).

[0037] The polymer may be the fiber itself or a binder to hold the pigment. In either case, the polymer becomes part of the fiber bundle superstructure.

[0038] As used herein, "adhesion" refers to the tendency of different surfaces to adhere to each other through dispersed adhesion forces, which are formed by attractive forces generated by the interaction between the molecules of each material.

[0039] As used herein, a "gap" is a crack, fissure or fissure on the surface of a fiber bundle, wherein the width of the gap on the surface is at least 1 nanometer to 10 micrometers and the volume of the gap occupies 15% to 90% of the volume of the fiber bundle.

[0040] As used herein, "air diffusion" is a technique for continuously applying a foreign material or a permanent coating to a fiber bundle under stable temperature-humidity conditions. The principle of this wet continuity is based on the principle of equal chemical potential.

[0041] As used herein, "fixing" is a chemical process that produces hardening or strengthening of a polymer material by cross-linking polymer chains by exposing them to a temperature gradient.

[0042] As used herein, "penetration" refers to the extent to which the coating material and the thermoplastic polymer penetrate into the surface of the fiber bundle to form a core-shell structure with the fiber bundle as the core and the coating as the shell, preferably at least 20 volume % of the gaps are filled with the thermoplastic polymer and the coating material, more preferably at least 50 volume %, and most preferably up to about 90 volume % of the gaps are filled with the thermoplastic polymer and the coating material.

[0043] The present invention will be described with reference to the accompanying drawings, which are an integral part of the specification but do not constitute a limitation of the present invention and are provided for the clarity of the present invention. In each of the accompanying drawings, similar elements will be numbered according to the accompanying drawings.

[0044] Reference Figure 1 Embodiments of the present invention are described. Figure 1 In the figure, the fiber material 10 is schematically represented as being provided from a supply system in the form of a laterally separated single strand of fiber material. The dry fiber material is provided according to the known techniques in the art, and no other modifications are made here. It is understood that the fiber material schematically shown in the figure represents a superstructure, a fiber assembly, a filament or a fiber. For the sake of clarity, the fiber material is in a tension state and travels in the direction of the arrow in each figure. Each strand of fiber material passes through a plasma treatment element 12, wherein the plasma treatment element preferably includes a comb 13, which ensures that the fiber material is separated and substantially parallel. The fiber material is preferably under sufficient tension to maintain a substantially parallel orientation so as to pass through a discharge device 14, which is preferably a high-voltage plasma corona discharge device. In some embodiments, it is preferred to present the fiber material on a plane, with the distance between the single strands being in the nanometer range, but not entangled. The discharge device is preferably operated at a maximum energy of 6kW, which is sufficient to damage the surface of each strand of fiber material, thereby creating gaps inside it, producing a treated fiber material 102. There is no particular limit to the speed through the comb and the discharge device, but it must be balanced with the ever-present demand for production efficiency under the constraint of sufficient residence time for adequate treatment. Speeds of about 3 meters to about 100 meters per minute are sufficient to demonstrate the present invention, with the understanding that increasing the plasma discharge energy may allow for increased speeds and decreasing the plasma discharge energy may allow for decreased speeds.

[0045] Reference Figure 2Embodiments of the present invention are described. Figure 2 In the process, the treated fiber bundle 102 passes through the ultrasonic treatment element 30, wherein the treated fiber bundle is immersed in the surfactant 22, preferably immersed in the surfactant pool, wherein the surfactant is activated by the ultrasonic energy, resulting in a wet fiber bundle 104. The surfactant in the ultrasonic treatment element can be a cationic surfactant, an anionic surfactant or an acidic surfactant. As is known in the art, a roller 21 can be provided to control the path through the surfactant. The ultrasonic energy is sufficient to cause the surfactant to enter the gap of the treated fiber bundle, thereby at least partially impregnating the treated fiber bundle with the surfactant.

[0046] In particularly preferred embodiments, the ultrasonic treatment element is configured to allow any surfactant that does not adhere to the wetted fiber bundle to return to or remain in the surfactant pool, thereby reducing material loss.

[0047] Reference Figure 3 Embodiments of the present invention are described. Figure 3 In the embodiment of the present invention, the wet fiber bundle 104 preferably passes through a holding station 23, wherein the wet fiber bundle is subjected to additional ultrasonic energy, preferably in the absence of additional surfactant. The ultrasonic energy further enhances the penetration of the surfactant into the interstitial regions of the fiber bundle, which are created by the corona plasma treatment. The ultrasonic energy produces an impregnated fiber bundle 106. A series of idler rollers 24 control the path of the fiber bundle through the holding station to ensure that the entire sample is treated with sufficient ultrasonic energy.

[0048] Reference Figure 4 An embodiment of the present invention is described in which a portion of a diffuser box 40 is shown in side view. Figure 4 In the embodiment, the diffusion box has a series of air diffusion devices 32, including nozzles 31, which subject the impregnated fiber bundle 106 to a pressurized spray 42, wherein the spray is in the form of droplets including a thermoplastic polymer and a coating material. In an embodiment, the droplets can be further activated by ultrasonic energy. Energy is applied by spraying and preferably additional ultrasonic energy to allow the coating material and the thermoplastic polymer to penetrate into the gap area initially produced by the plasma treatment and subsequently impregnated with a surfactant. The particle size of the thermoplastic polymer is preferably about 1 nanometer to 5 nanometers under an applied pressure of about 0.5 MPa to about 1.5 MPa. The particle size is selected to be sufficient to enter the interstitial surface of the gap, and the permeability is ensured by the previously applied surfactant and treatment. The thermoplastic polymer is preferably cured in a curing element 16, preferably at a curing temperature not exceeding about 200°C, more preferably about 130°C to 180°C, and the curing element 16 can be integrated with or separated from the diffusion box to produce a cured fiber bundle 108. The curing process fixes the polymer material by cross-linking adjacent polymer chains.

[0049] In a preferred embodiment, excess spray including thermoplastic polymer and coating material is collected and returned to the air diffusion device, thereby minimizing material loss.

[0050] Reference Figure 5 Embodiments of the present invention are described. Figure 5 In the embodiment, the solidifying fiber bundle 108 is optionally coated with a fixing coating 53 and a fixing coating 55 in the fixing element 50. The fixing coating mitigates the effects of oxidation, wear and other damages and provides a lubricating function to the surface, thereby providing a fixed fiber bundle 110. There is no particular limitation on the material suitable for use as the fixing coating, and a wide range of materials can be selected depending on the underlying material. Exemplary materials include, but are not limited to: modified polyurethane, especially for light colors, or if used for dark colors, preferably used with a crosslinking agent, such as a crosslinking agent provided by Archroma textilechemicals, acrylic adhesives, PVC, etc.

[0051] In a preferred embodiment, excess fixed coating is collected and returned to the fixed element device, thereby minimizing material loss.

[0052] Embodiments of the present invention are as follows Figure 6 As shown. Figure 6, a supply assembly 112 provides a fiber bundle 10 to a plasma treatment element 12, thereby forming a treated fiber bundle 102. The treated fiber bundle enters an ultrasonic treatment element 30, where the treated fiber bundle is converted into a wet fiber bundle 104. The wet fiber bundle enters a fixing station 23, thereby forming an impregnated fiber bundle 106. The impregnated fiber bundle passes through at least one diffusion box 40, and optionally through up to 10 diffusion boxes, thereby forming a cured fiber bundle 108, and then the fiber bundle passes through an additional wetting tank 16 containing a crosslinking agent to prepare a fiber bundle 109, and then optionally fixed in a fixing element 50. The fiber bundle 110 represents the finished product delivered. Although shown as linear, it should be understood that the various components discussed separately for convenience can be in various orientations and combinations. Ensuring that the entire cross-section of the fiber bundle is treated in each treatment can be achieved by using two elements, which substantially increases the effective residence time, or multiple passes in a unit, which also substantially increases the effective residence time, or by changing the path within or between treatment areas. Two treatment elements may also be used, wherein the treatment element is one of the elements of the present invention, including discharge devices, ultrasonic treatment elements or air diffusion devices, fixed elements, etc. The treatment elements may be two, with two elements treating each side, or the path of the fiber bundle may be changed, such as by rotation, flipping or redirection, to ensure that both sides are treated. In an embodiment, the fiber bundle may be parallel to the ground, with the treatment element below and above the ground, or at an angle relative to the ground, such as perpendicular to the treatment element on either side thereof, wherein the treatment is simultaneous or sequential.

[0053] The coating materials and thermoplastic polymers preferably have a particle size and chemical crosslinking capability to promote specific properties, such as changing aesthetics by including pigments or colorants, changing conductivity by including electrical insulators or conductors, obtaining antimicrobial properties by including antimicrobial materials, improving temperature resistance by including thermal conductors or thermal insulators, improving strength by including crosslinking agents, improving lubricity or anti-friction properties by including surface treatment materials, obtaining luminescence by introducing luminescent or light-absorbing materials, obtaining reflectivity by including optically reflective materials, obtaining gas separation properties by introducing pore formers, or obtaining environmental properties by including hydrophobic or hydrophilic materials.

[0054] Particularly preferred silk or fiber includes natural fiber, synthetic fiber, regenerated cellulose fiber or special fiber. Particularly preferred natural fiber includes: cotton, wool, silk fabric, flax, linen, hemp, jute, ramie, coconut shell fiber, sisal, alpaca, cashmere, mohair, angora goat hair, camel hair, camel hair, spider web fiber, etc. Particularly preferred synthetic fiber includes: glass fiber, carbon fiber, aramid, polyester, nylon 6, nylon 66, acrylic fiber, modacrylic fiber, spandex, elastic fiber, lycra cotton, olefin fiber, PVC fiber, polypropylene, polyethylene, etc. Particularly preferred regenerated cellulose fiber includes: bamboo fiber, synthetic protein fiber, synthetic spider web fiber, cuprammonium fiber, viscose fiber, acetate fiber, lyocell fiber, tencel, modal fiber, sorona fiber, soybean fiber, seaweed fiber, kapok fiber, etc. Particularly preferred specialty fibers include: gold, silver, copper, conductive fibers, antibacterial fibers (e.g., fibers containing silver or other materials), flame retardant fibers (e.g., polymers with mixed chemical compositions, brominated, chlorinated, or high-purity antimony trioxide), and the like.

[0055] The consolidated fiber bundle and optional fixed coating are suitable for use in many applications including aerospace, automotive applications, architectural applications, landscape applications, industrial applications, scientific applications, apparel, furniture, military applications, and the like.

[0056] The fiber bundles are usually provided from a single reel, package or beam, as is well known in the art. There is no particular limitation on the number of fiber bundles that can be simultaneously fed into the process of the present invention, and the process can be used between conventional feed systems and conventional finished product collection systems without modification. It is not uncommon in the art to feed as few as one and as many as 2,500 fiber bundles simultaneously, with limitations usually being space, demand and cost rather than technical limitations.

[0057] Speed ​​and tension are usually controlled outside the components of the present invention, with speed being controlled based on the rate of extension of the fiber bundle through the components of the present invention, and tension being controlled by the resistance on the rollers before the components of the present invention. The present invention does not limit tension and speed, except that some time is required in various components, and residence time is a function of power, such as in discharge devices or ultrasonic treatment elements, but residence time under treatment can be increased by slower transmission, increasing the number of rollers in the treatment area, or increasing the size of the treatment area, wherein the treatment area is the area being treated. Residence time under treatment can be reduced by faster transmission, reducing the number of rollers in the treatment area, thereby shortening the path, or reducing the size of the treatment area. As will be appreciated by those skilled in the art, each element of the method of the present invention can be optimized using conventional engineering principles.

[0058] A special feature of the present invention is the ability of the coating to adhere to the fiber bundle. Without being limited by theory, it is believed that the thermoplastic polymer and the coating enter the interstices of the fiber bundle. Once cured, the thermoplastic polymer has a mechanical advantage over the coating alone. The result is an encapsulated fiber bundle in which each filament of the fiber bundle is encapsulated in a cured thermoplastic polymer in a core-shell structure.

[0059] exist Figure 7 An embodiment of the present invention is schematically shown in a cross-sectional view of , wherein a coated filament 190 comprises a filament or fiber 200 as a core, the filament or fiber comprising at least one gap 202, wherein the gap has a thermoplastic polymer 204 penetrating and extending into the gap, wherein the thermoplastic polymer is cured together with the coating material. Figure 8 Another embodiment of the present invention is shown in FIG, wherein a fiber assembly 192 is shown including two filaments 200, each filament including at least one gap 202, wherein the gap has a thermoplastic polymer 204 penetrating or extending into the gap, wherein the thermoplastic polymer (including the coating material) is cured. Fig. 9 A plurality of fiber assemblies 192 are schematically illustrated being incorporated into a resin 204 to form a superstructure 206 .

[0060] In some embodiments, superstructure components or shapes are subjected to conditions of drying and heat, steam, or heat and steam, or other methods.

[0061] Example 1: Process flow

[0062] A series of individual superstructure assemblies or shapes ranging in length from 600 meters to 20,000 meters or more, or multiple fiber bundles up to 2,500 or more at a time, can be removed from a spool and introduced into an adjustable comb designed to ensure that the fiber bundles are closely aligned but not tangled or crossed, preferably with a spacing of about 1 nanometer to about 10 microns.

[0063] The fiber bundle is then stretched through a plasma treatment element with an energy of up to 6 kW, and subsequently stretched through a surfactant bath of about 100 liters to about 1000 liters containing anionic surfactants, cationic surfactants or acidic surfactants and mediated by ultrasonic energy of 0 kW to 3 kW to form a treated fiber bundle. This electrochemical process will enhance and expand the surface gaps in the fiber bundle, which can better retain the coating material in subsequent processes.

[0064] The treated fiber bundle will be stretched through a series of sinusoidal rollers in an ultrasonic treatment element with a total length of more than 75 meters, thereby improving permeability to form a wet fiber bundle.

[0065] A mixture of coating material and thermoplastic polymer is applied to the surface of the wetted fiber bundle at a specific pressure and speed to ensure that the entire surface of the material is coated with the appropriate material to impart pigment, antimicrobial properties, temperature resistance, strength enhancement, luminescence, reflective or environmental properties, water resistance or other desired properties. The fiber bundle is then exposed to a curing process to ensure that the coating is completely completed.

[0066] A fixed coating is applied, thereby protecting the fiber bundle from oxidation, abrasion and other potential damage.

[0067] Example 2: Carbon ribbon implementation scheme

[0068] With the advent of supertall buildings such as the Burj Khalifa in Dubai, which is 828 meters (2,716 feet) tall, or the Shanghai Tower in Shanghai, which is 632 meters (2,703 feet) tall, traditional steel hoisting cables, such as elevator hoist cables or "ropes", are now highly engineered and made of steel and other composite materials. Instead of a single wire, they are made of multiple strands of wire of various sizes twisted together. A typical cable or rope can have over 150 strands of steel wire, which are precisely designed to ensure strength, flexibility and long-term use. Multiple strands of steel wire are used to increase the life of the cable and give it flexibility, but these wires cannot be used in high-speed elevators or elevators used to transport passengers and freight. Conventional steel cables are limited to a length of about 500 meters (1,640 feet) because at this length, the weight of the hoisting rope on the hoisting motor and the sheave or pulley and axle loads become unbearable. A solution to the problem of more than 500 meters, especially in the Middle East, the European Union and the United States, is to use flat carbon ribbons instead of steel hoisting ropes. In Asia, there have been examples of circular carbon fiber superstructures being used. Flat carbon belts can be up to one kilometer in length, are 90% lighter, use less energy, produce less noise or "buzz" during lifting, and last longer. Unlike steel ropes, however, wear and damage are more difficult to detect, and all four sides of the belt must be inspected. Typical flat carbon belts for lifting applications are 250 mm (about 10 inches) wide, 50 mm (about 2 inches) thick, and come in lengths up to 2,500 meters (8,200 inches). This material is often treated with a protective polyurethane coating to provide a degree of lubrication and protection to the flat carbon belt.

[0069] Safety is a key certification requirement for elevators and hoists, and inspection protocols have existed for steel hoist ropes since the mid-1870s. A preliminary protocol has been developed for flat ribbons, but further refinement is needed. The present invention provides a colored protective coating for flat ribbons that replaces the standard polyurethane coating. The colored protective coating is intended to achieve three goals: First, to distinguish flat ribbon lengths by color. Second, to utilize the wear characteristics of the colored protective coating as an inspection tool. Inspection becomes easier as the color wears (less obvious color means more severe wear or damage) and can be accomplished through computer vision technology. Third, use of the present invention provides the required lubrication for the hoist pulley.

[0070] As a demonstration of the invention, a single flat carbon ribbon (250 mm (about 10 inches) wide, 50 mm (about 2 inches) thick, and 1000 meters (3280 feet) long) is shown after it has been manufactured and fully heat cured. This single flat carbon ribbon is placed on a dedicated reel for protective color coating and then reloaded onto another dedicated reel.

[0071] Superstructure components and shapes are coated using a continuous process technology where the colored protective coating is transferred from a unique air diffusion system without the use of traditional processing equipment, hazardous chemicals or large amounts of energy.

[0072] A single flat ribbon can be taken from a dedicated reel in lengths of approximately 1000 meters (3280 feet).

[0073] The flat carbon ribbon is moved on an alternating current (AC) electrode at a speed of 3 to 100 meters per minute, generating a corona plasma discharge of up to 6Kw, making the flat carbon ribbon more electrochemically adhesive or sticky.

[0074] The top flat ribbon will receive a 1 nm to 5 nm coating material, which is applied to the flat ribbon at a specific pressure (about 0.5 MPa to about 1.5 MPa) and speed (3 m / min to 100 m / min). Then, after the coating process, the flat ribbon is flipped 180 degrees to expose the bottom or untreated side.

[0075] The base of the superstructure component or shape is fed into the same enclosure to apply the coating material and thermoplastic polymer on the opposite side at a specific pressure and speed to ensure that the entire surface of the flat ribbon is coated with the appropriate material designed to impart color and wear or abrade at a specified rate. The flat ribbon is then exposed to a curing process to ensure that the coating is completely completed.

[0076] The final processing stage applies an adhesive coating to the flat ribbon. The adhesive coating seals the coating, providing additional protection and design.

[0077] Flat ribbons up to 1000 meters (3280 feet) long are removed from the process and placed on special reels.

[0078] The present invention has been described with reference to preferred embodiments but is not limited thereto. Those skilled in the art will recognize other embodiments described and set forth in the appended claims.

Claims

1. A fiber bundle comprising: at least one filament, wherein the filament comprises a surface having gaps in the surface; A thermoplastic polymer is cured on the surface, wherein the cured thermoplastic polymer includes a coating material, and the cured thermoplastic polymer and the coating material extend into the gap. 2 . The fiber bundle according to claim 1 , wherein the average size of the gaps is from 1 nanometer to 10 micrometers.

3. The fiber bundle of claim 1, wherein the interstitial volume of the interstitial spaces is at least 15% of the filament volume, wherein at least 20% of the interstitial volume is filled by the solidified thermoplastic polymer and the coating material.

4. The fiber bundle according to claim 1, wherein the average dimension of the width of the gaps on the surface of the filaments is 1 nanometer to 10 micrometers.

5. The fiber bundle of claim 4, wherein the interstitial volume does not exceed 90% of the volume of the fiber bundle.

6. The fiber bundle of claim 4, wherein up to 90% of the interstitial volume is filled with the solidified thermoplastic polymer and the coating material.

7. The fiber bundle of claim 1, wherein the fiber bundle comprises at most 2500 filaments.

8. The fiber bundle of claim 1, wherein the filaments are selected from the group consisting of natural fibers, synthetic fibers, regenerated cellulose fibers, and specialty fibers.

9. The fiber bundle according to claim 8, wherein the natural fiber is selected from cotton, wool, silk, flax, flax, hemp, jute, ramie, coconut shell fiber, sisal, alpaca, cashmere, mohair, angora goat wool / fleece, camel hair, camel hair, spider web fiber, etc.; particularly preferred synthetic fibers include: Fiberglass, carbon fiber, aramid, polyester, nylon 6, nylon 66, acrylic, modacrylic, spandex, elastane, lycra, olefin, PVC, polypropylene and polyethylene.

10. The fiber bundle according to claim 8, wherein the regenerated cellulose fiber is selected from the group consisting of bamboo fiber, synthetic protein fiber, synthetic spider web fiber, cupro fiber, viscose fiber, acetate fiber, lyocell fiber, tencel fiber, modal fiber, salona fiber, soybean fiber, seaweed fiber and kapok fiber.

11. The fiber bundle according to claim 8, wherein the specialty fibers are selected from gold, silver, copper, conductive fibers, antimicrobial fibers such as fibers containing silver or other materials, flame retardant fibers such as polymers with mixed chemical composition, brominated, chlorinated and high purity antimony trioxide.

12. The fiber bundle of claim 1, further comprising a surfactant in the interstices.

13. The fiber bundle according to claim 12, wherein the surfactant is selected from the group consisting of a cationic surfactant, an anionic surfactant and an acidic surfactant.

14. The fiber bundle according to claim 1, wherein the coating material is selected from the group consisting of pigments, electrical insulators, electrical conductors, antimicrobial materials, thermal conductors, thermal insulators, crosslinking agents, surface treatment materials, luminescent materials, light absorbing materials, light reflecting materials, pore formers, hydrophobic materials, and hydrophilic materials.

15. A fiber assembly comprising a plurality of the fiber bundles according to claim 1.

16. A superstructure comprising a plurality of fiber assemblies according to claim 15.

17. The fiber bundle of claim 1, wherein the thermoplastic polymer is selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, nylon, polystyrene, polyvinyl chloride, acrylonitrile butadiene styrene, ethylene vinyl acetate, thermoplastic polyurethane, polyolefin elastomers, poly(methyl methacrylate), poly(ethyl acrylate), poly(butyl acrylate), poly(2-ethylhexyl acrylate), poly(acrylic acid), and copolymers of acrylic acid.

18. The fiber bundle of claim 1, wherein the thermoplastic polymer is a copolymer comprising acrylic acid and at least one selected from the group consisting of styrene, acrylonitrile, and vinyl acetate.

19. A method of forming a coated fiber bundle, comprising: subjecting at least one fiber bundle to a plasma discharge to form a treated fiber bundle including gaps; treating the treated fiber bundle with a surfactant activated by ultrasonic energy to form a wetted fiber bundle; applying a thermoplastic polymer and a coating material to the wet fiber bundle to form an impregnated fiber bundle, wherein the thermoplastic polymer and the coating material impregnate the interstices; and The thermoplastic polymer is cured.

20. The method of forming a coated fiber bundle according to claim 19, further comprising exposing said wet fiber bundle to additional ultrasonic energy without additional surfactant prior to said forming said impregnated fiber bundle.

21. The method of forming a coated fiber bundle according to claim 20, wherein the ultrasonic energy has an energy of up to 3 Kw.

22. The method of forming a coated fiber strand according to claim 19, further comprising applying a fixing coating to the solidified fiber strand.

23. The method of forming a coated fiber bundle according to claim 19, comprising subjecting a plurality of fiber bundles to the plasma discharge to form a plurality of treated fiber bundles having a gap in each of the plurality of fiber bundles.

24. The method of forming coated fiber bundles according to claim 23, comprising separating the plurality of fiber bundles prior to the plasma discharge.

25. The method of forming a coated fiber bundle according to claim 23, wherein the plurality of fiber bundles are separated by 1 nanometer to 10 microns.

26. The method of forming a coated fiber bundle according to claim 19, wherein the ultrasonic energy has an energy of up to 6 Kw.

27. The method of forming a coated fiber strand according to claim 19, wherein the thermoplastic polymer and the coating material are applied at a pressure of 0.5 MPa to 1.5 MPa.

28. The method of forming a coated fiber bundle according to claim 19, wherein the average size of the gaps is from 1 nanometer to 10 microns.

29. The method of forming a coated fiber bundle according to claim 19, wherein the interstitial spaces have an interstitial volume of at least 15% of the filament volume, wherein at least 20% of the interstitial volume is filled with the solidified thermoplastic polymer and the coating material.

30. The method of forming a coated fiber bundle according to claim 19, wherein the gaps have an average dimension of 1 nanometer to 10 micrometers in width on the surface of the filaments.

31. The method of forming a coated fiber bundle of claim 30, wherein the interstitial volume does not exceed 90% of the superstructure volume.

32. The method of forming a coated fiber strand according to claim 30, wherein up to 90% of said interstitial volume is filled with said solidified thermoplastic polymer and said coating material.

33. The method of forming a coated fiber bundle according to claim 19, wherein the fiber bundle comprises at most 2500 filaments.

34. The method of forming a coated fiber strand according to claim 19, wherein the filaments are selected from the group consisting of natural fibers, synthetic fibers, regenerated cellulose fibers, and specialty fibers.

35. The method of forming a coated fiber bundle according to claim 34, wherein the natural fibers are selected from the group consisting of cotton, wool, silk, flax, flax, hemp, jute, ramie, coconut shell fiber, sisal, alpaca, cashmere, mohair, angora, camel, camel hair, spider web fibers, etc.; particularly preferred synthetic fibers include: Fiberglass, carbon fiber, aramid, polyester, nylon 6, nylon 66, acrylic, modacrylic, spandex, elastane, lycra, olefin, PVC, polypropylene and polyethylene.

36. The method of forming a coated fiber bundle according to claim 34, wherein the regenerated cellulose fiber is selected from the group consisting of bamboo fiber, synthetic protein fiber, synthetic spider web fiber, cupro fiber, viscose fiber, acetate fiber, lyocell fiber, tencel fiber, modal fiber, salona fiber, soy fiber, seaweed fiber and kapok fiber.

37. A method of forming a coated fiber bundle according to claim 34, wherein the specialty fibers are selected from gold, silver, copper, conductive fibers, antimicrobial fibers such as fibers containing silver or other materials, flame retardant fibers such as polymers with mixed chemical compositions, brominated, chlorinated and high purity antimony trioxide.

38. The method of forming a coated fiber bundle according to claim 19, further comprising a surfactant in the interstices.

39. The method of forming a coated fiber strand according to claim 38, wherein the surfactant is selected from the group consisting of a cationic surfactant, an anionic surfactant, and an acidic surfactant.

40. The method of forming a coated fiber strand according to claim 19, wherein the coating material is selected from the group consisting of.

41. The method of forming a coated fiber bundle according to claim 19, wherein the coating material is selected from the group consisting of pigments, electrical insulators, electrical conductors, antimicrobial materials, thermal conductors, thermal insulators, crosslinking agents, surface treatment materials, luminescent materials, light absorbing materials, light reflecting materials, pore formers, hydrophobic materials, and hydrophilic materials.

42. The method of forming a coated fiber strand according to claim 19, wherein the thermoplastic polymer is selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, nylon, polystyrene, polyvinyl chloride, acrylonitrile butadiene styrene, ethylene vinyl acetate, thermoplastic polyurethanes, polyolefin elastomers, poly(methyl methacrylate), poly(ethyl acrylate), poly(butyl acrylate), poly(2-ethylhexyl acrylate), poly(acrylic acid), and copolymers of acrylic acid.

43. The method of forming a coated fiber strand according to claim 19, wherein the thermoplastic polymer is a copolymer comprising acrylic acid and at least one selected from the group consisting of styrene, acrylonitrile, and vinyl acetate.

44. The method of forming a coated fiber strand according to claim 19, wherein the thermoplastic polymer particles have a particle size of 1 nanometer to 5 nanometers.

45. A fiber assembly formed by combining a plurality of fiber bundles according to claim 19 into a bundle.

46. ​​A superstructure formed by combining a plurality of fiber assemblies according to claim 46.

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