Textiles including recycled and bio-based content

Abstract

Various Aspects disclosed relate to a substrate material. The substrate material includes a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material. The substrate material further includes a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material.

Description

TEXTILES INCLUDING RECYCLED AND BIO-BASED CONTENTCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 63 / 426,359 entitled “TEXTILES INCLUDING RECYCLED AND BIOBASED CONTENT,” filed November 17, 2022, the disclosure of which is incorporated herein in its entirety by reference.BACKGROUND

[0002] There is a continuing trend towards the use of more sustainable materials for use in various fields, including textiles. At the same time, there is an expectation that the product and process performance is not compromised with the inclusion of materials that provide sustainability benefits, or if completely substituted with an alternative more sustainable polymer.SUMMARY

[0003] Various aspects disclosed relate to a substrate material. The substrate material includes a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material. The substrate material further includes a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material.

[0004] Various aspects disclosed relate to a method of making a substrate material. The substrate material includes a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material. The substrate material further includes a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material. The method includes dispersing the bio-based polymer component and the recycled polymer component about each other to form a dispersion or a blend.

[0005] Various aspects disclosed relate to a fiber that is formed from a substrate material. The substrate material includes a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material. The substrate material further includes a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material.Various aspects disclosed relate to a yarn that is made from a fiber formed from a substrate material, the substrate material includes a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material. The substrate material further includes a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material.

[0006] Various aspects disclosed relate to a fabric or a textile that is made from a yarn that is formed from a substrate material, the substrate material includes a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material. The substrate material further includes a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] Reference will now be made in detail to certain Aspects of the disclosed subject matter. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

[0008] Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “about X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

[0009] In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” or “at least one of A or B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intendedto aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

[0010] In the methods described herein, the acts can be carried out in any order without departing from the principles of the invention, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

[0011] The term “about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range, and includes the exact stated value or range. The term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

[0012] The term “substantially free of’ as used herein can mean having none or having a trivial amount of, such that the amount of material present does not affect the material properties of the composition including the material, such that about 0 wt% to about 5 wt% of the composition is the material, or about 0 wt% to about 1 wt%, or about 5 wt% or less, or less than or equal to about 4.5 wt%, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.01, or about 0.001 wt% or less, or about 0 wt%.

[0013] The term “weight-average molecular weight” as used herein refers to Mw, which is equal to SMi2ni / EMm, where nt is the number of molecules of molecular weight Mi. In various examples, the weight-average molecular weight can be determined using light scattering, small angle neutron scattering, X-ray scattering, and sedimentation velocity.

[0014] The term “polyamide” as used herein refers to polymer having repeating units linked by amide bonds. Polyamides may arise from monomers comprising aliphatic, semiaromatic or aromatic groups. Polyamide includes nylons, e.g., nylon-6, 6 or nylon-6, and may refer to polyamides arising from a single monomer, two different monomers, or three or more different monomers. The term polyamide thus includes dimonomeric polyamides. The polyamide may be a nylon having as monomer units a dicarboxylic acid monomer unit and a diamine monomer unit. For example, if the dicarboxylic acid monomer unit is adipic acid and the diamine is hexamethylene diamine, the resulting polyamide can be nylon-6, 6. Nylon-6 is a polyamidehaving a caprolactam monomer. The polyamide may be copolymers which may be prepared from aqueous solutions or blends of aqueous solutions that contain more than two monomers. In various aspects, polyamides can be manufactured by polymerization of dicarboxylic acid monomers and diamine monomers. In some cases, polyamides can be produced via polymerization of aminocarboxylic acids, aminonitriles, or lactams. Suitable polyamides include, but are not limited, to those polymerized from the monomer units described herein. The term “polyamide” includes polyamides such as PA6, PA66, PAI 1, PAI 2, PA612, Nylon-66 / 6T. However, this term can be modified, when done so expressly, to exclude particular polyamides. For example, in some aspects, the polyamide can be a polyamide other than PAI 1, PAI 2, and PA612; or the polyamide can be a polyamide other than Nylon-66 / 6T.

[0015] The term “N6,” “nylon-6,” or “PA6” as used herein, refers to a polymer synthesized by polycondensation of caprolactam. The polymer is also known as polyamide 6, nylon-6, and poly(caprolactam).

[0016] The term “N66,” “nylon-6, 6,” or “PA66” as used herein, refers to a polymer synthesized by polycondensation of hexamethylenediamine (HMD) and adipic acid. The polymer is also known as Polyamide 66, nylon-66, nylon-6-6, and nylon-6 / 6.

[0017] The polymers described herein can terminate in any suitable way. In some embodiments, the polymers can terminate with an end group that is independently chosen from a suitable polymerization initiator, -H, -OH, a substituted or unsubstituted (Ci-C2o)hydrocarbyl (e.g., (Ci-Cio)alkyl or (Ce-C2o)aryl) interrupted with 0, 1, 2, or 3 groups independently selected from -O-, substituted or unsubstituted -NH-, and -S-, a poly(substituted or unsubstituted (Ci- C2o)hydrocarbyloxy), and a poly(substituted or unsubstituted (Ci-C2o)hydrocarbylamino).

[0018] Generally, there are multiple options to achieve sustainability goals desired for producing a textile. This can include recycling, use of bio-based materials, or circular approaches. However, each approach provides its own sets of advantages and disadvantages. For example, an approach which only provides the aspect of recyclability via a recyclable polymer may not be meaningful if no such avenue for recycling is available, such as a lack of recycling infrastructure. In another case, the use of a biobased polymer may not be as helpful in achieving desired sustainability goals if the source of the biobased ingredients has high water and resource usage to obtain the materials. There is particular value in having optionality for both biobased and recycled content to optimize / control performance as well as the desired sustainability target.

[0019] Described herein are substrate materials that can be used to make a sustainable textile. The material includes a mixture including at least a bio-based polymer component and a recycled polymer component. Bio-based polymers are generally understood to be materials produced from renewable biomass sources, such as vegetable fats and oils, corn starch, straw, woodchips, sawdust, recycled food waste, and the like. Some bio-based polymers are obtained by processing directly from natural biopolymers including polysaccharides (e.g. starch, cellulose, chitosan and alginate) and proteins (e.g. soy protein, gluten and gelatin), while others are chemically synthesized from sugar derivatives (e.g. lactic acid) and lipids (oils and fats) from either plants or animals, or biologically generated by fermentation of sugars or lipids. In some examples, the bio-based polymer can be produced as a by-product or waste product from a process. In contrast, common plastics, such as fossil-fuel plastics (also called petro-based polymers) are derived from petroleum or natural gas

[0020] One advantage of bio-based polymers is their independence from fossil fuel as a raw material, which is a finite and globally unevenly distributed resource that is linked to petroleum politics and the environmental impacts. Life cycle analysis studies show that some bio-based polymers can be made with a lower carbon footprint than their fossil counterparts, for example when biomass is used as raw material and also for energy production. However, other bio-based polymers processes are less efficient and result in a higher carbon footprint than fossil plastics.

[0021] A polymer can be recycled by taking an existing waste feedstock and repurposing it for another use. As an example, a waste feedstock can be shredded into flakes or chips or fibers. The feedstock can be obtained from a municipal residential, commercial or industrial waste stream. In some examples the waste stream preferably has been sorted to remove metals, organics, or the like. Alternatively, a waste can be melt processed to form polymer pellets that are formed into new products.

[0022] While it is desirable to include bio-based polymers and a recycled polymer in a textile for various reasons, including the potentially positive environmental impact, there are certain drawbacks to including these materials in a textile. For example, a recycled polymer may not always be the pure form of the polymer that it was recycled from. The recycling process can result in physical impurities (e.g., other compounds) being intermingled with the recycled polymer. Impurities can include contaminants such as residual monomers, solvents, and othermaterials that can have different melting points These impurities can have several detrimental consequences such as impeding the processability of the recycled polymer. For example, the melting point of the polymer can be negatively impacted, the range of different melting points of the materials can make it difficult to predict the actual melting point of the recycled polymer, the compatibility of the recycled polymer with another material can be negatively impacted, particulate impurities can negatively impact fiber spinning yield or the like.

[0023] As described herein, the disclosed method works best when the melting point of the recycled polymer and the melting point of the bio-based polymer are within a certain range of each other. That is why it can be a problem when contaminants affect the melting point of the recycled polymer as described above, other problems associated with using recycled polymers can include degradation of the recycled polymer, variability in the feedstock of the recycled polymer, and the process conditions that the recycled polymer was exposed to during recycling. With respect to polymer degradation, during recycling, polymers can undergo degradation due to exposure to high temperatures, chemicals, or mechanical stress. Degraded polymers have lower molecular weights and may have different melting behavior than the original polymer. Predicting the melting point of a recycled polymer becomes difficult when significant degradation has occurred. With respect to the variability in feedstock, recycled polymers can come from a variety of sources, and the composition of the feedstock can vary widely. Even when recycling the same polymer, the feedstock may have different additives or processing conditions that can influence the melting point of the recycled material. With respect to processing conditions, the conditions used during the recycling process, such as temperature, pressure, and residence time, can influence the final properties of the recycled polymer, including its melting behavior. Predicting the melting point of a recycled polymer becomes challenging when there is variability in the processing conditions used to produce it.

[0024] While it is possible to “purify” a recycled polymer to remove these impurities or use a chemical recycling process, such a process is time consuming, less environmentally friendly and expensive and it may not be economical to conduct these processes to use a recycled polymer in a textile.

[0025] Bio-based polymers can similarly suffer from the presences on impurities. For example, the synthetic scheme used to produce the bio-based polymer can include side products, remaining reagent, fragmented product, or the like. Impurities such as these can lead to severalundesirable properties in the textile such as discoloration, emitting odors, undesirable physical properties (e.g., affecting the melting point of the bio-based polymer), or the like in the product. With respect to the synthetic scheme or the feedstock of the bio-based polymer, bio-based polymers can be produced from a wide range of feedstocks, including plants, bacteria, and algae. The exact composition of the feedstock can vary depending on factors such as growing conditions, harvesting techniques, and storage methods. Additionally, the processing conditions used to produce bio-based polymers can also influence their behavior. Indeed, factors such as temperature, pressure, and residence time can all affect the physical and chemical properties of the polymer, making it difficult to predict how the material will perform in different applications. Additionally, the use of different processing techniques, such as extrusion, injection molding, or blow molding, can also influence the behavior of bio-based polymers. This variability can make it challenging to predict the properties and behavior of bio-based polymers. With respect to potential fragmented product or degradation of the product, bio-based polymers can be subject to degradation over time, particularly if they are exposed to high temperatures, UV radiation, or other environmental stressors. Degradation can result in changes to the physical and chemical properties of the polymer, making it difficult to predict how the material will behave in different applications.

[0026] These can be overcome by purifying the product, however, purifying the product can add undesirable costs to the overall process of creating a product including the bio-based polymer.

[0027] This disclosure presents a solution to the aforementioned drawbacks. Namely, the instant disclosure recognizes that a combination of a bio-based polymer component and a recycled polymer component can overcome the drawbacks caused by the presence of the impurities associated with the respective products in an economical and / or more environmentally friendly way. This is because the respective concentrations of impurities in the final combined product are reduced compared to a product that exclusively includes the bio-based polymer component or the recycled polymer component. Because the concentrations of impurities associated with the bio-based polymer and the recycled polymer component are reduced, the potential negative impacts of the impurities are reduced. Therefore, in producing a product that includes a bio-based polymer component and a recycled polymer, the need to purify the recycled polymer component and bio-based polymer component is substantially mitigated. That is theproduct of the bio-based polymer reaction does not need to be thoroughly purified before use — to the extent that there are any impurities to remove. Similarly, the recycled polymer does not need to be completely processed or cleaned before use although it is within the scope of this disclosure to completely process or clean the recycled polymer before use. The product of this invention also offers improved recyclability at the end of life because of reduced concentration of impurities and dilution of the recycled polymer with the bio-based polymer.

[0028] Accordingly, according to various aspects, a substrate material (e.g., a pellet) can include a mixture of a bio-based polymer component and a recycled polymer component. The bio-based polymer component can be in a range of from about 5 wt% to about 95 wt% of the substrate material, about 30 wt% to about 70 wt%, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or about 95 wt% of the substrate material. The recycled polymer component can be in a range of from about 5 wt% to about 95 wt% of the substrate material, about 30 wt% to about 70 wt%, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or about 95 wt% of the substrate material. In some aspects, the respective concentrations of the biobased polymer component and the recycled polymer component in a substrate can be substantially the same. Alternatively, in some aspects the respective concentrations of the biobased polymer component and the recycled polymer component in a substrate can be different. The exact concentrations of the respective components can be selected based on the desired properties of the substrate material and the desired carbon footprint of the product.

[0029] The bio-based polymer component can include any suitable polymer. Examples of suitable polymers can include a polyamide, a polyester, a polysaccharide, a polyolefin (e.g., in some aspects a polyethylene), a polyhdroxyalkanoate, a polyurethane, a polyketone, or a mixture thereof. In certain aspects, the bio-based polymer is a polyamide or a polyester. Examples of suitable polyamides include nylon-6; nylon-6, 6; nylon-4, 6; nylon-5, 6; nylon-4, 10; nylon-5, 10; nylon-6, 10; nylon-7; nylon-11; nylon-12; a copolymer of nylon-6; a copolymer of nylon-6 or nylon-6, 6 having at least one repeating unit that is poly(hexamethylene terephtalamide), poly(hexamethylene isophthalamide), a copolymer of poly(hexamethylene terephtalamide) and poly(hexamethylene isophthalamide); a mixture thereof; or a copolymer thereof. Examples of suitable polyesters include a polylactic acid, a poly caprolactone, a polyhydroxyalkanoate, a polyhydroxybutyrate, a polyethylene adipate, a poly butylene succinate, a poly (3-hydroxy butyrate-co-3 -hydroxy valerate), a polyethylene terephthalate, a polybutylene terephthalate, a polytrimethylene terephthalate, a polyethylene naphthalate, a copolymer thereof, or a mixture thereof.

[0030] The recycled polymer component can include a polyamide, a polyester, a polysaccharide, a polyolefin, a polyhdroxyalkanoate, a polyurethane, a polyketone, or a mixture thereof. In certain aspects, the recycled polymer is a polyamide or a polyester. Examples of suitable polyamides include nylon-6; nylon-6, 6; nylon-4, 6; nylon-5, 6; nylon-4, 10; nylon-5, 10; nylon-6, 10; nylon-7; nylon-11; nylon-12; a copolymer of nylon-6; a copolymer of nylon-6 or nylon-6, 6 having at least one repeating unit that is poly(hexamethylene terephtalamide), poly(hexamethylene isophthalamide), a copolymer of poly(hexamethylene terephtalamide) and poly(hexamethylene isophthalamide); a mixture thereof; or a copolymer thereof. Examples of suitable polyesters include a polylactic acid, a poly caprolactone, a polyhydroxyalkanoate, a polyhydroxybutyrate, a polyethylene adipate, a poly butylene succinate, a poly (3- hydroxy butyrate-co-3 -hydroxy valerate), a polyethylene terephthalate, a polybutylene terephthalate, a polytrimethylene terephthalate, a polyethylene naphthalate, a copolymer thereof, or a mixture thereof.

[0031] The bio-based polymer component and the recycled polymer component can belong to the same class of polymer. For example, the bio-based polymer component and the recycled polymer component can both be a polyamide or both be a polyester. In some further aspects, the bio-based polymer component and the recycled polymer component are the same species of polymer. In some aspects where the bio-based polymer component and the recycled polymer component are the same species of polymer. The number of repeating units, order of repeating units, and / or weight-average molecular weight of the respective polymers can be the same or different.

[0032] It is possible for the substrate to include a non-bio-based polymer component, a nonrecycled polymer component, or a mixture thereof. Therefore, the substrate can include a mixture of recycled polymers and bio-based polymers along with other types of materials that are not recycled or bio-based. As an example, the nonrecycled polymer component independently comprise a polyamide, a polyester, a polyether, a polycarbonate, a polyolefin, a polystyrene, a polyacrylate, a polyvinyl chloride, a polyvinyl ether, a fluoropolymer, a copolymer thereof, or a mixture thereof. Thus, it is possible to include the recycled polymer component and bio-basedpolymer component in another material to increase the “green” or sustainable nature of the substrate.

[0033] The characteristics of the substrate material can be improved by having some degree of overlap or minimal difference in the properties of the bio-based polymer component and the recycled polymer. For example, an absolute value of a difference between a melting point of the bio-based polymer component and a melting point of the recycled polymer component is less than about 100 °C, less than about 50 °C, less than about 25 °C, less than about 10 °C, or substantially the same. As another example, a weight-average molecular weight of the bio-based polymer component and a weight-average molecular weight of the recycled polymer component are within about 50% of each other, within about 30% of each other, within about 20% of each other within about 10% of each other, or substantially the same. Possible difficulties associated with achieving the degree of overlap or minimal difference in the properties of the bio-based polymer component and the recycled polymer include the reactive recycled polymer and bio-based polymer component compositions. That is the chemical composition of polymers can vary widely, and this can affect their melting behavior. For example, some polymers may have a crystalline structure that makes them more difficult to melt than amorphous polymers. Additionally, polymers with different molecular weights, functional groups, or stereochemistry may have different melting points, making it difficult to match them. Other difficulties include the processing conditions used to produce recycled polymers and / or bio-based polymer component, which can also affect their melting behavior. For example, factors such as temperature, pressure, and residence time can all influence the melting point of the recycled polymers and / or bio-based polymer component. For example, polymers that have undergone significant thermal degradation during processing may have a lower melting point than expected. Another difficulty of matching the melting points can include the presence of any additives. For example, recycled polymers and / or bio-based polymer materials may include additives such as plasticizers, flame retardants, or fillers, which can affect their melting behavior. Some additives may increase the melting point of the material, while others may decrease it. The presence of additives can make it challenging to match melting points between different materials.

[0034] As a further example, a moisture content of the bio-based polymer component and the recycled polymer component are independently in a range of from about 50 ppm to about2000 ppm, 100 ppm to about 500 ppm, less than, equal to, or greater than about 50 ppm, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, or about 2000 ppm. Relative to each other, a moisture content of the bio-based polymer component and a moisture content of the recycled polymer component are within about 30% of each other, within about 20% of each other, within about 10% of each other, or substantially the same. Having overlap in at least one of the properties or in a combination of these properties can increase the compatibility of the bio-based polymer component and the recycled component, which can aid in processing the substrate and incorporating it into a material.

[0035] The substrate material can be formed into a fiber, which can generally be formed by an extrusion technique. If desired, the fiber can be a component of a yarn formed from a plurality of fibers. In a yarn, each of the fibers can be formed from the substrate or at least one fiber may not be formed from the substrate.

[0036] The fiber formed from the substrate or yarn including the fiber can be used to form a textile. A textile formed from the fiber or yarn, can be one of many different types of textiles. For example, the textile can be a non-woven textile. Examples of suitable non-woven textiles include a spun-bound non-woven textile, a melt-blown non-woven textile, a needle entangled nonwoven textile, or a water-entangled non-woven textile. Alternatively, the textile can be a woven textile, a braided textile, a knit textile, or a non-woven textile. In some examples, the textile can be formed from a collection of fibers that can be aligned in in substantially the same direction. In other examples, the textile can be formed from one or more yarns each including a plurality of first fibers 108.

[0037] Individual fibers or yarns mentioned herein can be incorporated into a textile in many different ways. For example, the fibers or yarn can entirely form the textile. Alternatively, the fibers or yarns may form only a portion of the textile. Alternatively, the fiber can be selectively incorporated into the textile. The textile can be incorporated into a garment (e.g., a shirt, pants, a hat, a glove, a workwear), a garment component (e.g., a patch or vent), bag, backpack, airbag, footwear (e.g., a shoe or a sock), or a footwear component (e.g., a lace or upper). In some examples, the textile defines the garment, garment component, footwear, or footwear component entirely. In other examples, the textile can define only a portion of thegarment, garment component, footwear, or footwear component. For example, the textile can range from about 5 wt% to about 100 wt% of the article, about 30 wt% to about 95 wt% of the article, about 50 wt% to about 90 wt% of the article, less than, equal to, or greater than about 5 wt%, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or about 100 wt%.

[0038] Various aspects of the present disclosure relate to a method of making the substrate material. The method can include dispersing the bio-based polymer component and the recycled polymer component about each other to form a dispersion or a blend. The blend of the bio-based polymer and the recycled polymer can be dried and fed to an extruder for fiber spinning. Water injection can be used with the extruder via closed loop to control melt viscosity in a fiber spinning machine. In some aspects, the bio-based polymer and the recycled polymer can be dried separately and then cofed to an extruder for fiber spinning. Separate drying (and / or solid-phase polymerization) with co-feeding of the two components allows for independent control of process conditions for the two components and easy adjustment of the ratio of the two components. Separate drying and feeding also eliminates possibility of gravity separation between the two components that could occur due to differences in shape and size of the pellets between the bio-based polymer and the recycled polymer. Gravity separation leads to nonuniform fiber composition and nonuniform fiber properties. The bio-based polymer can be supplied to a practitioner when making the substrate material. Alternatively the method of making the substrate material can include the steps of synthesizing the bio-based polymer as a step in the method. Similarly, the recycled polymer can be supplied to a practitioner when making the substrate material. However, it is also possible that the method of making the substrate material can include the steps of processing a waste to form the recycled polymer. The waste that is processed to form the recycled polymer may be a pre-consumer or post-consumer waste. In some aspects the waste that is processed to form the recycled polymer can come from a non-bio-based polymer, a bio-based polymer, a combination thereof.Examples

[0039] Various Aspects of the present invention can be better understood by reference to the following Examples which are offered by way of illustration. The present invention is not limited to the Examples given herein.

[0040] Various examples of chips and fibers include different substrate materials are developed and tested to determine their properties as shown herein below in Table 1.

[0041] A first substrate material includes 100 wt% virgin (conventional petro-based) Nylon-6, 6 (labeled “N66- 0% recycle, 0% Bio”, a second substrate material includes 100 wt% mechanically recycled Nylon-6, 6 (labeled “N66 - 100% recycle”), a third substrate material includes 100 wt% bio-based Nylon-6, 6 (labeled “N66 - 100% bio”), and fourth substrate material includes 50 wt% recycled Nylon-6, 6 and 50 wt% bio-based Nylon-6, 6 (“labeled N66 - 50% recycle, 50 % bio”).

[0042] Each substrate material is evaluated as a chip for its feedstock variability. Each chip is processed through extrusion to form a fiber. The fibers are evaluated for their tenacity, elongation at break, heat strength retention, and energy to break retention, and fiber fluff quality. The fibers are incorporated into a fabric textile. The fabric textiles are evaluated for their performance, expected cost, concentration (by wt%) of sustainably sourced material, and estimated CChe rating.

[0043] Testing to determine these properties is performed according to the following method. Nylon fiber samples are prepared by cutting fiber off a bobbin and conditioning it in an environment with a temperature of 24 (± 1) deg C and a relative humidity of 55 (± 2) %. The testing is performed using a CRE (Constant Rate of Extension) tensile tester. Before testing an internal calibration of the instrument is performed and the samples are pre-twisted to 3 TPI (twists per inch). The samples are then mounted vertically in a set of specialized grips called “yarn horns.” These grips allow the sample to be wrapped around each side of the grips until taut and then clamped pneumatically with 45 PSI to secure the fiber in place. The upper grip is mounted on a moving platform called a crosshead. The crosshead speed of the tester is set to a constant 12 in / min and the gauge length between grips is set to 254 mm. Testing is performed by moving the crosshead vertically until the fiber breaks. The fiber breaking strength (N) and yarn elongation at break (% gauge length) are measured by the tester during the test. Fiber tenacity is determined by dividing the breaking strength by the tex of the fiber. Energy to break is determined by calculating the area under the force-elongation curve (N-m).

[0044] A 3000-hour accelerated heat aging test for nylon fiber strength retention is then performed. This heat aging process is used as an indicator of real-world mechanical performance of fibers that are exposed to elevated temperatures over extended periods of time. A devicecalled a fiber “skein” winder is used to prepare samples (skeins) of fiber which are 100 m in length. The heat aging process takes place in an oven which is capable of a temperature of 110 (± 3) deg C. Oven temperature is validated using a calibrated thermocouple or other suitable measuring device before beginning the heat aging process. The fiber skeins are hung on a rod and placed in the oven, date and time of the commencement of heat aging is recorded. After 3000 hours the samples are removed and then tested according to a yarn break method. All testing must be completed within one week of the samples being removed from the oven to ensure quality. Results are compared to control samples tested without heat aging to determine the strength retention of heat aged samples.Table 1

[0045] The terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof,but it is recognized that various modifications are possible within the scope of the Aspects of the present invention. Thus, it should be understood that although the present invention has been specifically disclosed by specific Aspects and optional features, modification and variation of the concepts herein disclosed may be resorted to by those of ordinary skill in the art, and that such modifications and variations are considered to be within the scope of Aspects of the present invention.Exemplary Aspects.

[0046] The following exemplary Aspects are provided, the numbering of which is not to be construed as designating levels of importance:

[0047] Aspect 1 provides a substrate material, comprising: a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material; and a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material.

[0048] Aspect 2 provides the substrate material of Aspect 1, comprising: a bio-based polymer component that is about 30 wt% to about 70 wt% of the substrate material; and a recycled polymer component that is about 30 wt% to about 70 wt% of the substrate material.

[0049] Aspect 3 provides the substrate material of any one of Aspects 1 or 2, further comprises: a non-bio-based polymer component; a nonrecycled polymer component; or a mixture thereof.

[0050] Aspect 4 provides the substrate material of Aspect 3, wherein the non-bio-based polymer component and the nonrecycled polymer component independently comprise a polyamide, a polyester, a polyether, a polycarbonate, a polyolefin, a polystyrene, a polyacrylate, a polyvinyl chloride, a polyvinyl ether, a fluoropolymer, a copolymer thereof, or a mixture thereof.

[0051] Aspect 5 provides the substrate material of any one of Aspects 1-4, wherein the substrate material further comprises: an impurity formed during the production of the bio-based polymer component; an impurity formed during the production of the recycled polymer component; or a mixture thereof.

[0052] Aspect 6 provides the substrate material of Aspect 5, wherein the impurity formed during the production of the bio-based polymer component comprises a side-reaction product, a reagent, a degraded bio-based polymer component, or a mixture thereof.

[0053] Aspect 7 provides the substrate material of any of Aspects 5 or 6, wherein the impurity formed during the production of the recycled polymer component comprises a solvent, a degraded recycled polymer component, or a mixture thereof.

[0054] Aspect 8 provides the substrate of any of Aspects 5-7, wherein a combined concentration of the impurity formed during the production of the bio-based polymer component and the impurity formed during the production of the recycled polymer component is less than a concentration of a corresponding substrate formed from either an unpurified bio-based polymer component or an unpurified recycled polymer component.

[0055] Aspect 9 provides the substrate of any of Aspects 1-8, wherein the bio-based polymer component, the recycled polymer component, or both are unpurified.

[0056] Aspect 10 provides the substrate material of any one of Aspects 1-5, wherein the bio-based polymer component comprises a polyamide, a polyester, a polysaccharide, a polyolefin, a polyhdroxyalkanoate, a polyurethane, a polyketone, or a mixture thereof.

[0057] Aspect 11 provides the substrate material of any one of Aspects 1-6, wherein the bio-based polymer component comprises a polyamide, a polyester, or a mixture thereof.

[0058] Aspect 12 provides the substrate material of any one of Aspects 1-7, wherein the bio-based polymer component comprises a polyamide.

[0059] Aspect 13 provides the substrate material of any one of Aspects 1-8, wherein the recycled polymer component comprises a polyamide, a polyester, a polysaccharide, a polyolefin, a polyhdroxyalkanoate, a polyurethane, a polyketone, or a mixture thereof.

[0060] Aspect 14 provides the substrate material of any one of Aspects 1-9, wherein the recycled polymer component comprises a polyamide.

[0061] Aspect 15 provides the substrate material of any one of Aspects 7-10, wherein the polyamide of the bio-based polymer component and the recycled polymer component independently comprises: nylon-6; nylon-6, 6; nylon-4, 6; nylon-5, 6 ; nylon-5, 10 ; nylon-4, 10 ; nylon-6, 10; nylon-7 ; nylon-11; nylon- 12; a copolymer of nylon-6, a copolymer of nylon-6 or nylon-6, 6 having at least one repeating unit that is poly(hexamethylene terephtalamide), poly(hexamethylene isophthalamide), or a copolymer of poly(hexamethylene terephtalamide) and poly(hexamethylene isophthalamide); a mixture thereof; or a copolymer thereof.

[0062] Aspect 16 provides the substrate material of any one of Aspects 7-15, wherein the polyester of at least one of the bio-based polymer component and the recycled polymer component comprises a polylactic acid, a polycaprolactone, a polyhydroxyalkanoate, a polyhydroxybutyrate, a polyethylene adipate, a poly butylene succinate, a poly (3- hydroxybutyrate-co-3 -hydroxy valerate), a polyethylene terephthalate, a polybutylene terephthalate, a polytrimethylene terephthalate, a polyethylene naphthalate, a copolymer thereof, or a mixture thereof.

[0063] Aspect 17 provides the substrate material of any one of Aspects 1-16, wherein the bio-based polymer component and the recycled polymer component belong to the same class of polymer.

[0064] Aspect 18 provides the substrate material of any one of Aspects 1-17, wherein the bio-based polymer component and the recycled polymer component are the same polymer.

[0065] Aspect 19 provides the substrate material of any one of Aspects 1-18, wherein an absolute value of a difference between a melting point of the bio-based polymer component and a melting point of the recycled polymer component is less than about 100 °C.

[0066] Aspect 20 provides the substrate material of any one of Aspects 1-19, wherein an absolute value of a difference between a melting point of the bio-based polymer component and a melting point of the recycled polymer component is less than about 50 °C.

[0067] Aspect 21 provides the substrate material of any one of Aspects 1-20, wherein an absolute value of a difference between a melting point of the bio-based polymer component and a melting point of the recycled polymer component is less than about 25 °C.

[0068] Aspect 22 provides the substrate material of any one of Aspects 1-21, wherein an absolute value of a difference between a melting point of the bio-based polymer component and a melting point of the recycled polymer component is less than about 10 °C.

[0069] Aspect 23 provides the substrate material of any one of Aspects 1-22, wherein a melting point of the bio-based polymer component and a melting point of the recycled polymer component is substantially the same.

[0070] Aspect 24 provides the substrate material of any one of Aspects 1-23, wherein a weight-average molecular weight of the bio-based polymer component and a weight-average molecular weight of the recycled polymer component are within about 50% of each other.

[0071] Aspect 25 provides the substrate material of any one of Aspects 1-24, wherein a weight-average molecular weight of the bio-based polymer component and a weight-average molecular weight of the recycled polymer component are within about 20% of each other.

[0072] Aspect 26 provides the substrate material of any one of Aspects 1-25, wherein a weight-average molecular weight of the bio-based polymer component and a weight-average molecular weight of the recycled polymer component are within about 10% of each other.

[0073] Aspect 27 provides the substrate material of any one of Aspects 1-26, wherein a weight-average molecular weight of the bio-based polymer component and a weight-average molecular weight of the recycled polymer component is substantially the same.

[0074] Aspect 28 provides the substrate material of any one of Aspects 1-27, wherein a moisture content of the bio-based polymer component and the recycled polymer component are independently in a range of from about 50 ppm to about 2000 ppm.

[0075] Aspect 29 provides the substrate material of any one of Aspects 1-28, wherein a moisture content of the bio-based polymer component and the recycled polymer component are independently in a range of from about 100 ppm to about 500 ppm.

[0076] Aspect 30 provides the substrate material of any one of Aspects 1-29 wherein a moisture content of the bio-based polymer component and a moisture content of the recycled polymer component are within about 30% of each other.

[0077] Aspect 31 provides the substrate material of any one of Aspects 1-30, wherein a moisture content of the bio-based polymer component and a moisture content of the recycled polymer component are within about 20% of each other.

[0078] Aspect 32 provides the substrate material of any one of Aspects 1-31, wherein a moisture content of the bio-based polymer component and a moisture content of the recycled polymer component are within about 10% of each other.

[0079] Aspect 33 provides the substrate material of any one of Aspects 1-32, wherein a moisture content of the bio-based polymer component and a moisture content of the recycled polymer component are substantially the same.

[0080] Aspect 34 provides a method of making the substrate material of any one of Aspects 1-33, the method comprising: dispersing the bio-based polymer component and the recycled polymer component about each other to form a dispersion.

[0081] Aspect 35 provides the method of Aspect 34, further comprising drying the blend.

[0082] Aspect 36 provides the method of any one of Aspects 34 or 35, further comprising separately drying bio-based polymer component and the recycled polymer component.

[0083] Aspect 37 provides the method of Aspect 36, further comprising co-feeding the bio-based polymer component and the recycled polymer component to an extruder.

[0084] Aspect 38 provides the method of any one of Aspects 34-37, further comprising synthesizing the bio-based polymer.

[0085] Aspect 39 provides the method of any one of Aspects 34-38, further comprising processing a polymer component to form the recycled polymer component.

[0086] Aspect 40 provides the method of Aspect 39, wherein the polymer component is a virgin polymer component, a previously recycled polymer component, or a mixture thereof.

[0087] Aspect 41 provides the method of Aspect 40, wherein the virgin polymer component, a previously recycled polymer component, or a mixture thereof, comprise: a non-bio-based polymer; a bio-based polymer; or a combination thereof.

[0088] Aspect 42 provides a fiber comprising the substrate material of any one of Aspects 1-41.

[0089] Aspect 43 provides a method of forming the fiber of Aspect 42, the method comprising extruding the substrate material.

[0090] Aspect 44 provides a yarn comprising a plurality of fibers, wherein at least one of the plurality of fibers is the fiber of Aspect 43.

[0091] Aspect 45 provides a textile comprising the fiber of Aspect 44, the yarn of Aspect 40, or both.

[0092] Aspect 46 provides the textile of Aspect 45, wherein the textile is a non-woven textile.

[0093] Aspect 47 provides the textile of any one of Aspects 45 or 46, wherein the nonwoven textile is a spun-bound non-woven textile, a melt-blown non-woven textile, a needle entangled non-woven textile, or a water-entangled non-woven textile.

[0094] Aspect 48 provides the textile of any one of Aspects 45-47, wherein the textile is a woven textile, a braided textile, a knit textile, or a non-woven textile.

[0095] Aspect 49 provides the textile of any one of Aspects 45-48, wherein the textile is a knit textile.

[0096] Aspect 50 provides an article comprising the textile of any one of Aspects 45-49, wherein the textile comprises about 5 wt% to about 100 wt% of the article.

[0097] Aspect 51 provides an article comprising the textile of any one of Aspects 45-50, wherein the textile comprises about 30 wt% to about 95 wt% of the article.

[0098] Aspect 52 provides an article comprising the textile of any one of Aspects 46-51, wherein the textile comprises about 50 wt% to about 90 wt% of the article.

[0099] Aspect 53 provides a clothing article comprising the textile of any one of Aspects 45-52.

[0100] Aspect 54 provides the article of Aspect 53, wherein the article of clothing comprises headwear, a garment, footwear, or a combination thereof.

Claims

CLAIMSWhat is claimed is:

1. A substrate material, comprising: a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material; and a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material wherein an absolute value of a difference between a melting point of the bio-based polymer component and a melting point of the recycled polymer component is less than about 50 °C.

2. The substrate material of claim 1, comprising: a bio-based polymer component that is about 30 wt% to about 70 wt% of the substrate material; and a recycled polymer component that is about 30 wt% to about 70 wt% of the substrate material.

3. The substrate material of claim 1, further comprises: a non-bio-based polymer component; a nonrecycled polymer component; or a mixture thereof.

4. The substrate material of claim 3, wherein the non-bio-based polymer component and the nonrecycled polymer component independently comprise a polyamide, a polyester, a polyether, a polycarbonate, a polyolefin, a polystyrene, a polyacrylate, a polyvinyl chloride, a polyvinyl ether, a fluoropolymer, a copolymer thereof, or a mixture thereof.

5. The substrate material of claim 1, wherein the bio-based polymer component comprises a polyamide, a polyester, a polysaccharide, a polyolefin, a polyhdroxyalkanoate, a polyurethane, a polyketone, or a mixture thereof.

6. The substrate material of claim 1, wherein the recycled polymer component comprises a polyamide, a polyester, a polysaccharide, a polyolefin, a polyhdroxyalkanoate, a polyurethane, a polyketone, or a mixture thereof.

7. The substrate material of claim 6, wherein the polyamide of the bio-based polymer component and the recycled polymer component independently comprises: nylon-6; nylon-6, 6; nylon-4, 6; nylon-5, 6; nylon-5, 10; nylon-4, 10; nylon-6, 10; nylon-7; nylon-11; nylon- 12; a copolymer of nylon-6, a copolymer of nylon-6 or nylon-6, 6 having at least one repeating unit that is poly(hexamethylene terephtalamide), poly(hexamethylene isophthalamide), or a copolymer of poly(hexamethylene terephtalamide) and poly(hexamethylene isophthalamide); a mixture thereof; or a copolymer thereof.

8. The substrate material of claim 1, wherein the bio-based polymer component and the recycled polymer component belong to the same class of polymer.

9. The substrate material of claim 1, wherein the recycled polymer component comprises a mechanically recycled polymer.

10. The substrate material of claim 1, wherein the substrate material further comprises: an impurity formed during the production of the bio-based polymer component; an impurity formed during the production of the recycled polymer component; or a mixture thereof11. The substrate material of claim 10, wherein the impurity formed during the production of the bio-based polymer component comprises a side-reaction product, a reagent, a degraded biobased polymer component, or a mixture thereof.

12. The substrate material of claim 10, wherein the impurity formed during the production of the recycled polymer component comprises a solvent, a degraded recycled polymer component, or a mixture thereof.

13. The substrate of claim 10, wherein a combined concentration of the impurity formed during the production of the bio-based polymer component and the impurity formed during the production of the recycled polymer component is less than a concentration of a corresponding substrate formed from either an unpurified bio-based polymer component or an unpurified recycled polymer component.

14. The substrate of claim 1, wherein the bio-based polymer component, the recycled polymer component, or both are unpurified.

15. A method of making a substrate material, the method comprising: dispersing the bio-based polymer component and the recycled polymer component about each other to form a dispersion or a blend.

16. The method of claim 15, further comprising drying the blend.

17. The method of claim 15, further comprising separately drying bio-based polymer component and the recycled polymer component.

18. The method of claim 17, further comprising co-feeding the bio-based polymer component and the recycled polymer component to an extruder.

19. The method of claim 15, further comprising subjecting the bio-based polymer component, the recycled polymer component, or both to solid-phase polymerization.

20. The method of claim 15, further comprising adjustably controlling the molecular weight of the bio-based polymer component, the recycled polymer component, or both.

21. The method of claim 17, further comprising water injection to an extruder via closed loop to control melt viscosity in a fiber spinning machine.

22. The method of claim 15, wherein the substrate material further comprises: an impurity formed during the production of the bio-based polymer component; an impurity formed during the production of the recycled polymer component; or a mixture thereof23. The method of claim 22, wherein the impurity formed during the production of the biobased polymer component comprises a side-reaction product, a reagent, a degraded bio-based polymer component, or a mixture thereof.

24. The method of claim 22, wherein the impurity formed during the production of the recycled polymer component comprises a solvent, a degraded recycled polymer component, or a mixture thereof.

25. The method claim 22, wherein a combined concentration of the impurity formed during the production of the bio-based polymer component and the impurity formed during the production of the recycled polymer component is less than a concentration of a corresponding substrate formed from either an unpurified bio-based polymer component or an unpurified recycled polymer component.

26. The method of claim 15, wherein the bio-based polymer component, the recycled polymer component, or both are unpurified.

27. A textile comprising: a fiber comprising: a bio-based polymer component that is about 5 wt% to about 95 wt% of the substrate material; and a recycled polymer component that is about 5 wt% to about 95 wt% of the substrate material.

28. The textile of claim 27, wherein the textile is a woven textile, a braided textile, a knit textile, or a non-woven textile.

29. The textile of claim 27, wherein the textile is a knit textile.

30. The textile of claim 27, wherein the textile comprises a yarn comprising the fiber.

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