Aerogel coated woven or knitted fabric

Abstract

The invention relates to an aerogel-coated, flame-retardant, waterproof woven or knitted fabric with anti-mold and anti-fungal properties for use as an insulating surface in textiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation.

Description

[0001] DESCRIPTION

[0002] AEROGEL COATED WOVEN OR KNITTED FABRIC

[0003] TECHNICAL FIELD

[0004] The invention relates to an aerogel-coated, flame-retardant, waterproof woven or knitted fabric with anti-mold and anti-fungal properties for use as an insulating surface in textiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation.

[0005] BACKGROUND OF THE INVENTION

[0006] Aerogels, the lightest solid material on earth, are defined as aerated foam containing between 95% and 99.9% air, with the remainder being a glass-like material, such as silicon dioxide, also known as silica. Air molecules trapped at nanometric size cannot move. This gives this material its high thermal insulation properties. This is also the case for sound insulation, and due to the compressed air molecules, the material's transmission of sound waves is minimized, making aerogel material a good sound insulation material. It also has many different physical and chemical properties. Aerogel is a glass-like material with the appearance of frozen smoke and can therefore be used on building facades.

[0007] Aerogels are porous synthetic materials obtained by replacing the liquid component of gels with gas. Although its name suggests a liquid, it is in fact a solid and dry material. “A gel refers to a mixture of two components, one a solid and the other a dispersing agent. If the dispersing agent is air, the structure formed is defined as aerogel, and if it is water, it is defined as hydrogel. The subject of this study is “aerogels” where the dispersing agent is air. The good thermal insulation of aerogels can be explained as follows: Two thin sweaters warm better than one thick sweater because of the air layer in between them. This is because the air layer between the two layers provides thermal insulation. In aerogel, this air layer is also present in high proportion and therefore thermal insulation is very good.

[0008] The general properties of aerogels can be summarized as follows: - Low thermal conductivity,

[0009] - Low dielectric constant,

[0010] - Low sound transmission rate,

[0011] - High specific surface area,

[0012] - High refractive index value,

[0013] - Low relative density and

[0014] - High porosity.

[0015] Regarding patent applications in the state of the art, the patent document numbered “US7635411B2” and titled “Aerogel Containing Cover” describes “the surface obtained by drying and calendering (crushing) the slurry of hydrophobic aerogel, textile fibers and at least one wetting agent". While the lowest thermal conductivity value that can be achieved in the related invention is > 0.020 W / mK, in the invention claimed by us, it can be reduced to 0.014 W / mK (0.047 m2K / W) (See Test report in the detailed description of the invention).

[0016] This means that the invention claimed by us has a lower thermal conductivity, i.e. it is a better insulating material. In addition, in the related patent “US7635411 B2”, the textile fibers are not in the form of woven or knitted fabrics, the fibers are combined in an irregular state and thus the resulting cover has a low strength (is non-durable), unlike woven or knitted structures.

[0017] “In the document numbered “US7078359B2” and titled “Aerogel Composite obtained by Needling Fibers”, the invention describes the production of Aerogel nonwoven fabric by a “needle-punch” like method (needling). The subject of the relevant US patent is lower strength (flimsy) than the superstructure proposed by us due to the manufacturing method by which it was obtained. The fibers are more easily separated from each other.

[0018] In the document numbered “US20070154698A1” and titled “Highly Flexible Aerogel Entrapped Textile-Like Covers”, the invention refers to perforated and / or fiber-reinforced, flexible, moisture-permeable aerogel structures in strip form. The subject matter of the invention proposed by us is not permeable, on the contrary, it presents a super structure that prevents permeability and provides insulation. Being perforated and permeable, it is impossible for the relevant US patent to provide thermal insulation as good as the invention proposed by us.

[0019] Thus, the need to eliminate such shortcomings and disadvantages of the embodiments and practices employed in the prior art entails an improvement in the respective technical field.

[0020] DESCRIPTION OF THE INVENTION

[0021] The present disclosure relates to an aerogel-coated, flame-retardant, waterproof woven or knitted fabric with anti-mold and anti-fungal properties developed for eliminating the aforementioned disadvantages and providing new advantages to the respective technical field.

[0022] The aim of the invention is to provide a waterproof, flame retardant and anti-mold- anti-fungal (mold and fungus repellent) multifunctional superstructure in the form of knitted or woven fabric by combining yarns obtained from textile fibers in a certain order and in a dense form by weaving or knitting techniques, which is coated by a dispersion containing silica aerogel in such a way that it is free of any voids, does not allow heat conduction (insulator), and in which irregular fiber placement is eliminated, resulting in a stronger, more durable structure.

[0023] Another aim of the invention is to provide a product that is resistant to household washing at 90 C.

[0024] Another aim of the invention is to provide a durable product which provides good insulation.

[0025] Another aim of the invention is to provide a superstructure that is not permeable, but rather prevents permeability and provides insulation.

[0026] Another object of the invention is to make the subject matter of the invention durable, as a result of the regular and dense structure of the knitted or woven fabric. DETAILED DESCRIPTION OF THE INVENTION

[0027] The preferred alternatives of the embodiments of invention, which are mentioned in this detailed description, are only intended for providing a better understanding of the subject-matter, and should not be construed in any restrictive sense.

[0028] The invention comprises, by weight, 25-84% of knitted or woven fabric with flame retardant and anti-mold and anti-fungal properties, 15-25% of waterproof (coated) film and 1-50% of aerogel containing coating dispersion.

[0029] The preferred amounts by weight in the invention are 56% of knitted or woven fabric with flame retardant and anti-mold and anti-fungal properties, 21 % of waterproof (coated) film and 23% of aerogel containing coating dispersion. However, the range we have given above does not change the resulting value of the invention.

[0030] The production method of the invention consists of the following process steps:

[0031] 1- Obtaining knitted or woven fabric from textile yarns by knitting or weaving,

[0032] 2- Transfer of chemicals that can provide anti-fungal and anti-mold, flame retardant properties to knitted or woven fabric by impregnating the fabric with them,

[0033] 3- Permanent bonding of chemicals providing anti-fungal and flame retardant properties to knitted or woven fabric by mechanical action (temperature),

[0034] 4- Coating one side of a knitted or woven fabric with flame retardant and antimold and anti-fungal properties with a waterproof film,

[0035] 5- Permanent bonding of a waterproof film to a knitted or woven fabric with flame retardant and anti-mold and anti-fungal properties by mechanical effects (temperature and compression pressure),

[0036] 6- Preparing by mixing the aerogel with the coating dispersion that will form the film layer in which the aerogel will be entrapped,

[0037] 7- Transfer of the aerogel containing coating dispersion to the uncoated side of the knitted or woven fabric on a coating basis, 8- Permanent bonding of the aerogel containing coating dispersion on the fabric to the knitted or woven fabric by mechanical effects (temperature and printing pressure).

[0038] Knitted fabric is the looping of yams with needles and the formation of a flexible and elastic surface. The yams of knitted fabrics are interlocked with a needle. It has an elastic and porous structure. Knitted fabric includes weft knitted fabrics and warp knitted fabrics.

[0039] Knitted fabrics have many advantages.

[0040] Flexibility: The stretchy structure of knitted fabrics increases freedom of movement. This is ideal for use in clothing and sportswear.

[0041] Air Permeability: Knitted fabrics have a structure that allows air flow. This reduces perspiration and helps users stay comfortable and cool.

[0042] Fast Production: The knitting process is generally faster than the weaving process. This supports mass production and fast delivery, especially important for the apparel industry.

[0043] Color Options: Knitted fabrics are available in a variety of colors and patterns. This gives designers and manufacturers the flexibility to produce products in different styles and in line with fashion trends.

[0044] Comfortability: These fabrics give a soft feel when in contact with the skin and are comfortable to wear.

[0045] Woven fabric includes all types of woven fabric. It is a type of fabric formed by threading yams perpendicular or curved to each other. This type of fabric is characterized by its durability and longevity. Generally widely used in the textile industry, woven fabrics are preferred in many areas from dresses to home textiles. Woven fabric has a durable, flexible and highly air permeable structure. It is used in many areas such as clothing, home textiles and decoration. It is realized by interlocking yams on warp and weft looms. It has the advantages of being durable, easy to shape and long-lasting.

[0046] These two types of fabric make the subject matter of the invention durable through their regular and dense structure. The textile yams comprising the knitted or woven fabric may contain all polymers (cotton, flax, hemp, jute, sisal, abaca, wool, alpaca, polyester, polyamide, polyimide, polyacrylonitrile -acrylic-, polyolefin -polyethylene, polypropylene-, aramid, elastane, etc., recycled / recovered forms thereof or mixtures thereof in different proportions) that give the product the characteristic of textile yam. Knitted or woven fabrics of the invention are produced by warp knitting, flat knitting (tricotage) or circular knitting techniques, and woven fabrics are produced by using textile yarns in dobby or jacquard weaving machines.

[0047] Zinc metal salts (in solution) are used to impart anti-mold and anti-fungal properties to the knitted or woven fabric of the invention, and alkyl phosphonate (in solution) is used to impart flame retardancy thereto. For each property, both chemicals are applied to the fabric in a solution of 15-35% of the dry weight of the fabric and then the wet fabric is dried. The dry fabric is exposed to high temperature to permanently bind both chemicals to the knitted or woven fabric.

[0048] In order to make one side of a knitted or woven fabric with anti-mold and anti-fungal and flame retardant properties highly waterproof, a film layer consisting of polyurethane, crosslinker, pure water and anionic / nonionic surfactant-phosphonate mixture is coated and the coated fabric is dried. This process is repeated once more to ensure that the film layer is free of any voids. The process does not have a significant negative impact on the breathability of the fabric by virtue of the structure of the polyurethane. The dry fabric is exposed to high temperature to permanently bind chemical to the knitted or woven fabric. The components of waterproofing coatings include:

[0049] - 91.3% liquid, aliphatic, anionic polyether-ester based polyurethane dispersion,

[0050] - 0.5% cross-linking agent

[0051] - 7.7% purified water,

[0052] - 0.5% anionic / nonionic surfactant-phosphonate mixture.

[0053] Aerogel containing coating dispersion is obtained by mixing with a mechanical mixer a water-based component that is in the liquid phase and capable of forming a solid film layer when dried, and silica aerogel in the form of solid particles. The aerogel and the coating dispersion that will form the film layer in which the aerogel will be entrapped are mixed by means of a mechanical mixer, preferably in the range of 50-1000 rpm. The weight ratio of aerogel particles to the coating dispersion is between 0.1 % and 30.0% by weight.

[0054] “Aerogel containing coating dispersion” is transferred on the basis of coating on 'flame retardant, waterproof knitted or woven fabric with anti-mold and anti-fungal properties'. The proportion of “Aerogel containing coating dispersion” in the total product weight is between 1 % and 50%.

[0055] The aerogel containing dispersion-coated “flame retardant, waterproof knitted or woven fabric with anti-mold and anti-fungal properties” is first dried and then exposed to 160-170°C for 0.5-1 minute to ensure permanent bonding of the aerogel containing coating dispersion to the “flame retardant, waterproof knitted or woven fabric with anti-mold and anti-fungal properties”.

[0056] In our invention, it is crucial that the liquid coating dispersion in which the aerogel particles will be entrapped is water-based. In addition, during the coating process, it must be ensured that the aerogel containing coating dispersion covers the flame retardant, waterproof knitted or woven fabric with anti-mold and anti-fungal properties in such a way that no voids remain.

[0057] The main component in the liquid phase of the aerogel containing coating dispersion is an aliphatic, anionic polyether-ester derived water-based polyurethane dispersion. Acrylic, latex or silicone-based liquids can also be used to trap the aerogel in a film layer and coat it onto a “flame-retardant, waterproof knitted or woven fabric with anti-mold and anti-fungal properties”.

[0058] Especially the reasons for creating a polyurethane membrane are as follows:

[0059] Polyurethane-based especially waterproofing materials are durable and long- lasting. High performance polyurethane liquid membrane is water tight. It is resistant to UV rays. It is characterized by high hydrophobia. It does not fade when exposed to sunlight due to its durable structure. They are elastomeric materials that provide good chemical and mechanical resistance. It therefore gives the subject matter of the invention a serious insulating feature.

[0060] - It contains 53.9%-85.4% liquid, aliphatic, anionic polyether-ester based polyurethane dispersion,

[0061] - 0.1 %-30.0% solid silica aerogel,

[0062] - 14.4%-16% purified water,

[0063] - 0.1 % anionic / nonionic surfactant-phosphonate mixture.

[0064] The top layer of the invention consists of an aerogel containing coating dispersion, the bottom layer consists of a knitted or woven fabric with anti-mold and anti-fungal properties, and the bottom layer consists of a waterproof (coated) film.

[0065] The invention comprises, by weight, 25-84% of knitted or woven fabric with flame retardant and anti-mold and anti-fungal properties, 15-25% of waterproof (coated) film and 1-50% of aerogel containing coating dispersion.

[0066] The anti-mold - anti-fungal activity test report of our invention is given below. The unfinished coded fabric is the untreated fabric and the finished coded fabric represents our invention. As can be seen here, our invention shows a high level of anti-mold - anti-fungal activity.

[0067]

[0068] Document No.: 20240118-02

[0069] 18 January 2024 Attention to Zeyd Tekstil - Ozan PARER,

[0070] Antimicrobial tests were performed on the fabric samples you have sent with different codes according to the AATCC 30 Standard Test Method at Bursa llludag University Antimicrobial Activity Test Laboratory and the results are given in Annex 1.

[0071] Sincerely,

[0072] Annex 1. Anti-fungal Test Results According to AATCC 30 Test Method (3 pages) Annex 1. Anti-fungal Test Results According to AATCC 30 Test Method (4 pages)

[0073] Test Report

[0074] Evaluation

[0075] Antimicrobial tests were performed on the fabric samples you have sent with different codes according to the AATCC 20 Standard Test Method at Bursa llludag University Antimicrobial Activity Test Laboratory.

[0076] When the results of the study with Candida albicans were analyzed after 72 hours of incubation, it was observed that there were fungal growths on and around the fabric samples coded Unfinished, while there were no fungal growths on and around the fabric samples coded Finished.

[0077] As a result, the tested Finished coded fabric samples were found to have an anti-fungal activity against Candida albicans.

[0078] Prof. Dr fifehmst O H NI

[0079] This report is intended to support the product development processes of private and legal persons. All rights reserved. It may not be reproduced, distributed, used for advertising purposes or for any other purpose unless authorized by the Agency.

[0080] Annex 1. Anti-fungal Test Results According to AATCC 30 Test Method (18 January 2024)

[0081] Page 1 / 3 Method

[0082] The antifungal activities of your fabric samples with different codes were tested according to the AATCC 30 test method. During the study, Candida albicans was transferred onto BD Sabouraud Dextrose Agar medium at a density of 1 .5x105 cfu* / mL and dispersed homogeneously. Your samples to be tested were placed on the solidified medium and incubated at 40°C for 72 hours. After 72 hours, the zones formed on the media were evaluated. To achieve acceptable anti-fungal activity, there should be no growth on and around the specimens in direct contact with Candida albicans.

[0083] This report is intended to support the product development processes of private and legal persons. All rights reserved. It may not be reproduced, distributed, used for advertising purposes or for any other purpose unless authorized by the Agency.

[0084] Annex 1. Anti-fungal Test Results According to AATCC 30 Test Method (18 January 2024)

[0085] Page 2 / 3 Evaluation of Test Results

[0086] Anti-fungal tests were performed on the fabric samples you have sent with different codes according to the AATCC 30 Standard Test Method at Bursa llludag University Antimicrobial Activity Test Laboratory and the results are given in Table 1 and Figure 1 .

[0087] Table 1. Anti-fungal Activity Values of Your Samples According to AATCC 30 Test

[0088] Method

[0089] * Each BD Sabouraud Dextrose Agar medium was inoculated with fungi at a concentration of 0.5 Mcfarland (-1.5x105 cfu* / mL).

[0090] Unfinished coded fabrics Finished coded fabrics

[0091] Figure 1. Anti-fungal Activity Values of Your Samples According to AATCC 30 Test

[0092] Method

[0093] When the results in Table 1 and Figure 1 are reviewed, it is seen that there are fungal growths on and around the fabric samples with unfinished code, while there are no fungal growths on and around the fabric samples with finished code.

[0094] This report is intended to support the product development processes of private and legal persons. All rights reserved. It may not be reproduced, distributed, used for advertising purposes or for any other purpose unless authorized by the Agency.

[0095] Annex 1. Anti-fungal Test Results According to AATCC 30 Test Method (18 January 2024)

[0096] Page 3 / 3 The flame retardancy test report of our invention is given below. The sample coded fabric represents our invention. As seen here, our invention meets the flame retardancy criteria according to the relevant test standard (NFPA 701 ).

[0097] BUTEKOM

[0098] Bursa Technology Coordination and R&D Center Test Report 2024-0412

[0099] 03-24 Table 2- It is the experimental result of the invention.

[0100] TEST RESULTS The waterproof test report of our invention is given below. The sample coded fabric represents our invention. As can be seen here, our invention has a very high water proofing, even above the level that the tester can test. The final use of the present invention is for tents or ground covers, and in the market, tent fabrics meeting the 5 value of 3000 mmHzOin the relevant field are sold in the class of tent fabrics with a high level (top segment) of water proofing.

[0101] Page 1 / 2

[0102] Table 3- It is the experimental result of the invention.

[0103] Page 2 / 2 The thermal resistance test report of our invention is given below. Sample 1 is a standard, untreated fabric and sample 5 represents our invention. As shown here, the thermal resistance of our invention is greater. This proves that a durable product

[0104] 5 that provides good insulation has been made.

[0105] Page 1 / 2

[0106] Table 4- It is the result of an experiment in which the subject matter of the invention is compared with an untreated product.

[0107] Page 2 / 2

Claims

CLAIMS1- A production method of the aerogel-coated, flame-retardant, waterproof woven or knitted fabric with anti-mold and anti-fungal properties for use as an insulating surface in textiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation, chracterized in that it includes the process steps of:- Obtaining knitted or woven fabric from textile yarns by knitting or weaving,- Transfer of chemicals that can provide anti-fungal and anti-mold, flame retardant properties to knitted or woven fabric by impregnating the fabric with them,- Permanent bonding of chemicals providing anti-fungal and flame retardant properties to knitted or woven fabric by mechanical action (temperature),- Coating one side of a knitted or woven fabric with flame retardant and antimold and anti-fungal properties with a waterproof film,- Permanent bonding of a waterproof film to a knitted or woven fabric with flame retardant and anti-mold and anti-fungal properties by mechanical effects (temperature and compression pressure),- Mixing and preparing the aerogel and the coating dispersion that will form the film layer in which the aerogel will be entrapped by means of a mechanical mixer in the range of 50-1000 rpm,- Transferring aerogel containing coating dispersion on the basis of coating on flame retardant, waterproof knitted or woven fabric with anti-mold and antifungal properties,- Firstly drying the aerogel containing coating dispersion on the fabric, then permanently bonding it to a flame retardant, waterproof knitted or woven fabric with anti-mold and anti-fungal properties by exposure to 160-170°C temperature for 0.5-1 min.2- The aerogel-coated, flame-retardant, waterproof woven or knitted fabric with anti-mold and anti-fungal properties for use as an insulating surface intextiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation, characterized in that it comprises, by weight,- 25%-84% knitted or woven fabric with flame retardant and anti-mold and anti-fungal properties,- 15-25% waterproof (coated) film,- 1 %-50% aerogel containing coating dispersion.3- The aerogel containing coating dispersion formulation for use as an insulating surface in textiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation, characterized in that it comprises, by weight,- 91.3% liquid, aliphatic, anionic polyether-ester based polyurethane dispersion,- 0.1 %-30.0% solid silica aerogel,- 14.4%-16% purified water,- 0.1 % anionic / nonionic surfactant-phosphonate mixture.4- The aerogel containing coating dispersion formulation for use as an insulating surface in textiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation according to claim 3, characterized in that acrylic, latex or silicone based fluids can also be used as an alternative to polyurethane.5- The waterproof (coated) film on aerogel-coated, flame-retardant, waterproof woven or knitted fabric with anti-mold and anti-fungal properties for use as an insulating surface in textiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation according to claim 2, characterized in that it comprises, by weight,- 91.3% liquid, aliphatic, anionic polyether-ester based polyurethane dispersion,- 0.5% cross-linking agent- 7.7% purified water,- 0.5% anionic / nonionic surfactant-phosphonate mixture.6- The aerogel-coated, flame-retardant, waterproof woven or knitted fabric with anti-mold and anti-fungal properties for use as an insulating surface in textiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation according to claim 2, characterized in that the fabric contains zinc metal salts solution (in solution) between 15-35% of the dry weight of the fabric, which provides the invention with anti-mold and anti-fungal properties.7- The aerogel-coated, flame-retardant, waterproof woven or knitted fabric with anti-mold and anti-fungal properties for use as an insulating surface in textiles, technical textiles, apparel, construction, insulation, outdoor activities (tents), outdoor needs (ground and ground covers), aerospace and aviation according to claim 2, characterized in that the fabric contains alkyl phosphonate solution (in solution) between 15-35% of the dry weight of the fabric, which provides the invention with flame retardancy properties.

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