Fibrous structures having improved moisture transport

Abstract

The present specification generally relates to a novel polyhydroxyalkanoate-polypropylene fiber alloy having significantly improved moisture absorption and wicking properties compared to conventional polypropylene fibers. The alloy is produced by combining a polyhydroxyalkanoate-polymer with a polypropylene polymer using a compatibilizer additive package and melt-spinning the resulting composition into multi-filament yarns. This innovative material offers a sustainable and cost-effective solution for applications requiring enhanced moisture management.

Description

95610.11916FIBROUS STRUCTURES HAVING IMPROVED MOISTURE TRANSPORT CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US Provisional Patent Application No.63 / 750,064, filed January 27, 2025, the entire contents of which is incorporated by reference herein.FIELD

[0002] Aspects of the present disclosure relate to fiber alloys having improved moisture absorption and / or wicking properties as compared to conventional fibers, such as polypropylene fibers.BACKGROUND

[0003] Moisture management in fabrics plays a crucial role in determining their comfort, functionality, and suitability for various applications, particularly in activewear, outdoor clothing, diapers, bed linens, and technical textiles. Moisture-wicking and absorption fabrics are two key categories designed to handle moisture, but they achieve this goal through different mechanisms and are optimized for specific uses. A need exists for fibrous structures that can be used to generate fabrics or other materials having significantly improved moisture absorption and wicking properties compared to conventional fibers.SUMMARY

[0004] Moisture management in fabrics plays a crucial role in determining their comfort, functionality, and suitability for various applications, particularly in activewear, outdoor clothing, diapers, bed linens, and technical textiles. Moisture-wicking and absorption fabrics are two key categories designed to handle moisture, but they achieve this goal through different mechanisms and are optimized for specific uses. Moisture-wicking fabrics are engineered to pull sweat or moisture away from the skin and transfer it to the outer surface of the fabric, where it can evaporate quickly. This process helps keep the wearer dry and comfortable, even during intense physical activity. Absorption fabrics, in contrast, are designed to retain moisture. They are typically made from hydrophilic fibers, which attract and hold water. These fabrics prioritize the ability to absorb and store liquids, making them ideal for specific applications such as cleaning, drying, or comfort in low-intensity settings.

[0005] Unlike traditional fabrics, which can absorb moisture and retain it against the skin, moisture-wicking fabrics use capillary action to pull moisture away from the surface of the skin to the outer layer of the fabric. Once there, the moisture spreads out 14900-0239-706695610.11916across a larger surface area, allowing it to evaporate more quickly. This keeps the skin dry and comfortable, even during intense physical activity or prolonged wear. Absorption fabrics, in contrast, are designed to retain moisture. They are typically made from hydrophilic fibers, which attract and hold water. These fabrics prioritize the ability to absorb and store liquids, making them ideal for specific applications such as cleaning, drying, or comfort in low-intensity settings. While moisture-wicking and absorption fabrics have distinct roles, they are not mutually exclusive and can sometimes be used in combination. For instance, hybrid garments may include an inner moisture-wicking layer to keep the skin dry and an outer absorption layer to retain moisture when needed. The choice between these fabric types depends on the intended use and the level of activity or comfort required.

[0006] The process of moisture wicking is enabled by the unique structure of these fabrics, often achieved by combining hydrophilic (water-attracting) and hydrophobic (water-repelling) fibers. This dual-layer system ensures that moisture is drawn away efficiently while preventing the fabric from becoming saturated. The result is a material that not only regulates body temperature by preventing excessive moisture buildup but also reduces the risk of skin irritation, chafing, or discomfort caused by wet clothing. Moisture-wicking fabrics are engineered to handle perspiration by efficiently moving moisture (sweat) away from the body and promoting rapid evaporation. Unlike traditional fabrics, which can absorb moisture and retain it against the skin, these fabrics use capillary action to pull sweat away from the surface of the skin to the outer layer of the fabric. Once there, the moisture spreads out across a larger surface area, allowing it to evaporate more quickly. This keeps the skin dry and comfortable, even during intense physical activity or prolonged wear.

[0007] Moisture-wicking fabrics are often made from synthetic fibers, such as polypropylene, that are inherently hydrophobic. These fabrics and fibers resist absorbing water, enabling sweat to move through the fabric instead of soaking in. These fabrics are typically woven or treated to create fine capillaries that facilitate the movement of moisture along the surface of the fibers. This mechanism ensures rapid transport of sweat from the skin to the outer layer of the fabric. This quality makes synthetic fibers, such as polypropylene, particularly effective for base layers in athletic and performance wear, as it ensures the skin remains dry even in high-sweat scenarios. In contrast, absorption fabrics are often made from natural fibers such as cotton, rayon, or bamboo, which have high water-retention capacities. Cotton, for instance, can absorb up to 25 times its weight in 24900-0239-706695610.11916water due to its cellulose structure. The fibers in absorption fabrics have an open structure, allowing them to soak up moisture easily. Additionally, these fabrics are usually woven or knit to maximize surface area for greater absorption

[0008] In addition to its wicking properties, synthetic fibers, such as polypropylene, are lightweight, strong, and thermally insulating, providing comfort across a range of environments. Their resistance to moisture absorption also prevents odor buildup, as bacteria thrive less in dry conditions. Unfortunately, as a major drawback to its hydrophobicity, polypropylene does not absorb moisture as quickly or completely as desired in many applications, such as in diapers and wipes, resulting in the need for more polypropylene material to achieve a desired moisture uptake capacity: increasing both cost and plastics usage.

[0009] Additionally, polypropylene being non-polar and chemically inert makes it challenging to dye or print on. As a result, the color options for polypropylene fabrics are often more limited, requiring extrusion-based pigment addition during production. This limitation can reduce design flexibility and increase production costs compared to other materials, and result in the combination of multiple polymers in a single application that reduce recyclability.

[0010] Thus, a need exists for providing polypropylene materials having significantly improved moisture absorption and wicking properties compared to conventional polypropylene fibers for enhanced moisture management and colorability.

[0011] There is provided for herein, in several embodiments, a material alloy for a woven or non-woven fiber comprising a first thermoplastic polymer comprising a polyhydroxyalkanoate, a second thermoplastic polymer, wherein the second thermoplastic polymer is not a polyhydroxyalkanoate, and a compatibilizer package, wherein the compatibilizer comprises a third polymer.

[0012] In several embodiments, the polyhydroxyalkanoate is between about 0.01 and about 40 parts by mass of the total mass of the alloy, including about 0.01 parts, about 0.05 parts, about 0.1 parts, about 0.5 parts, about 1 part, about 2 parts, about 3 parts, about 5 parts, aboutlO parts, about 15 parts, about 20 parts, about 25 parts, about30 parts, about 35 parts, about 40 parts or any amount therebetween. In several embodiments, the second thermoplastic polymer is between about 50 and about 99.9 parts by mass of a total mass of the alloy, including about 50 parts, about 55 parts, about 60 parts, about 65 parts, about 70 parts, about 75 parts, about 80 parts, about 85 parts, about 90 parts, about 95 parts,34900-0239-706695610.11916about 96 parts, about, about 97 parts, about 98 parts, about 99 parts, about 99.1 parts, about 99.3 parts, about 99.5 parts, about 99.7 parts, about 99.9 parts, and any amount therebetween. In several embodiments, the compatibilizer is between about 0.01 to about 20 parts by mass of the total mass of the alloy, and including about 0.01 parts, about 0.05 parts, about 0.1 parts, about 0.5 parts, about 1 part, about 2 parts, about 3 parts, about 5 parts, aboutlO parts, about 15 parts, about 20 parts, or any amount therebetween. In several embodiments, the parts of each component of the alloy are with respect to the total mass of the alloy being 100 parts by mass.

[0013] In several embodiments, the compatibilizer comprises a polyolefin elastomer and an acrylic acid-propylene copolymer.

[0014] In several embodiments, the polyhydroxyalkanoate comprises a polyhydroxybutyrate. In several embodiments, the polyhydroxyalkanoate is a carbonnegative polyhydroxyalkanoate . In several embodiments, the polyhydroxyalkanoate is a carbon-negative polyhydroxybutyrate. In several embodiments, the polyhydroxyalkanoate comprises one or more of PHB, PHBV, P(3HB-co-3HHx), P(3HB-co-4HB), or blends thereof.

[0015] In several embodiments, the polyhydroxyalkanoate comprises one of polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), polyhydroxybutyratecovalerate (PHBV), polyhydroxyhexanoate (PHHx) and blends thereof, and short chain length (SCL), medium chain length (MCL), and long chain length (LCL) PHAs.

[0016] In several embodiments, the polyhydroxyalkanoate comprises one or more of polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), polyhydroxybutyrate-coval erate (PHBV), polyhydroxyhexanoate (PHHx), poly 3-hydroxyalkanoates (e.g., poly 3 -hydroxypropionate (hereinafter referred to as P3HP), poly 3 -hydroxybutyrate (hereinafter referred to as PHB) and poly 3 -hydroxy valerate), poly 4-hydroxyalkanoates (e.g., poly 4-hydroxybutyrate (hereinafter referred to as P4HB), or poly 4-hydroxyvalerate (hereinafter referred to as P4HV)) and poly 5 -hydroxy alkanoates (e.g., poly 5-hydroxyvalerate (hereinafter referred to as P5HV)), poly 3-hydroxybutyrate-co-3-hydroxypropionate (hereinafter referred to as PHB3HP), poly 3-hydroxybutyrate-co-4-hydroxybutyrate (hereinafter referred to as PHB4HB), poly 3-hydroxybutyrate-co-4-hydroxy valerate (hereinafter referred to as PHB4HV), poly 3-hydroxybutyrate-co-3-hydroxy valerate (hereinafter referred to as PHB3HV), poly 3-hydroxybutyrate-co-3-hydroxyhexanoate (hereinafter referred to as PHB3HH) and poly 3-hydroxybutyrate-co-5-44900-0239-706695610.11916hydroxy valerate (hereinafter referred to as PHB5HV) and various combinations thereof, including polymer blends.

[0017] In several embodiments, the polyhydroxyalkanoate comprises virgin PHA, recycled PHA, or modified PHA (e.g., end-capped, grafted, or chain-extended).

[0018] In several embodiments, the second thermoplastic polymer comprises polypropylene, polyethylene terephthalate, polylactic acid, or combinations thereof. In several embodiments, the second thermoplastic polymer comprises polypropylene. In several embodiments, the polypropylene comprises a polypropylene homopolymer. In several embodiments, the polypropylene homopolymer is between about 80 parts and about 99.9 parts by mass, with respect to a total of 100 parts by mass of said alloy.

[0019] In several embodiments, the polyhydroxyalkanoate is between about 10 parts and about 2 parts by mass, and said compatibilizer package is between about 2 and about 8 parts by mass with respect to a total of 100 parts by mass of said alloy.

[0020] In several embodiments, the second thermoplastic polymer is between about 85 parts and about 99 parts by mass, said polyhydroxyalkanoate is between about 7 parts and about 4 parts by mass, and said compatibilizer package is between about 2 and about 4 parts by mass with respect to a total of 100 parts by mass of said alloy.

[0021] In several embodiments, the compatibilizer package comprises a polyolefin elastomer that has both metallocene and non-metallocene with elastomeric properties.

[0022] In several embodiments, the alloy further comprises a nonthermoplastic polymer. In several embodiments, the non-thermoplastic polymer comprises a semi-synthetic cellulose fiber, a synthetic cellulose fiber, or a natural cellulose fiber. In several embodiments, the non-thermoplastic polymer comprises Tencel™. In several embodiments, the non-thermoplastic polymer comprises cellulose.

[0023] In several embodiments, the material alloy has a vertical wicking rate that is double that of virgin polypropylene or other suitable control thermoplastic polymer. In several embodiments, the material alloy has a moisture absorption rate that is double that of virgin polypropylene or other suitable control thermoplastic polymer.

[0024] In several embodiments, the alloy is suitable for processing by a meltblown, spunblown, spunbond, injection molding, compression molding, blow54900-0239-706695610.11916molding, rotational molding, extrusion, thermoforming, calendaring, casting, fiber spinning, compounding, or 3D printing process.

[0025] In several embodiments, the alloy is suitable for processing to generate a non-woven fiber, a multifilament fiber, a monofilament fiber, a stable fiber, a tape yam, or a geotextile.

[0026] In several embodiments, further comprises one or more additional fiber components. In several embodiments, the one or more additional fiber components is selected from the group consisting of natural fibers, regenerated cellulosic fibers, biobased synthetic fibers, inorganic, carbon and / or metal fiber, aramid fibers, polybenzoxazole fibers, conductive or anti-static fibers, flame-retardant fibers, antimicrobial fibers, superabsorbent fibers and / or bicomponent binder fibers, or combinations thereof. In several embodiments, the additional fiber components enhances one or more of the feel, texture, breathability, durability, colorability, stain resistance, odor resistance, sun protection factor or other characteristic of an article manufactured in whole or in part with the alloy comprising the additional fiber(s).

[0027] Also provided for herein is a hydroxyalkanoate-polypropylene fiber alloy comprising a polypropylene, wherein the polypropylene is between about 60 and about 99.9 parts by mass of a total mass of the alloy, a polyhydroxybutyrate, wherein the polyhydroxybutyrate is between about 0.1 and about 30 parts by mass of the total mass of the alloy; and a compatibilizer package, wherein the compatibilizer comprises a polyolefin elastomer and an acrylic acid-propylene copolymer, wherein the compatibilizer is between about 0.1 to about 15 parts by mass of the total mass of the alloy, and wherein the total mass of the alloy is 100 parts by mass.

[0028] Additionally provided for herein is a material alloy for a woven or non-woven fiber comprising a polyhydroxyalkanoate, wherein the polyhydroxyalkanoate is between about 0.1 and about 30 parts by mass of the total mass of the alloy; and a non-polyhydroxyalkanoate thermoplastic polymer, wherein the non- polyhydroxyalkanoate thermoplastic polymer is between about 70 and about 99.9 parts by mass of a total mass of the alloy, a compatibilizer package, wherein the compatibilizer comprises an elastomer and a copolymer, wherein the compatibilizer is between about 0.1 to about 15 parts by mass of the total mass of the alloy, and wherein the total mass of the alloy is 100 parts by mass. In several embodiments, the compatibilizer comprises a polyolefin elastomer and an acrylic acid-propylene copolymer.64900-0239-706695610.11916

[0029] The present specification generally relates to a novel polyhydroxyalkanoate-polypropylene fiber alloy having significantly improved moisture absorption and wicking properties compared to conventional polypropylene fibers. In several embodiments, the alloy is produced by combining a polyhydroxyalkanoate-polymer with a polypropylene polymer using a compatibilizer additive package and melt-spinning the resulting composition into multi-filament yarns. This innovative material offers a sustainable and cost-effective solution for applications requiring enhanced moisture management.

[0030] Accordingly, the object of various embodiments of the present invention can be defined by a polyhydroxyalkanoate-polypropylene resin composition comprising an olefin-based polymer A (“polymer A”), a polyhydroxyalkanoate polymer B (“polymer B”), and a compatibilizer package C, wherein the polymer A is selected from the group consisting of an ethylene-based polymer, a propylene-based polymer, and a butene-based polymer, and may be a combination of any two or more thereof, wherein the polymer B is a poly(hydroxyalkanoate)-based polymer having a melting point of 100 °C to 220 °C, wherein the compatibilizer package C is an additive comprising an acrylic acid-propylene copolymer and a polyolefin elastomer or a combination of both, and the content of polymer A is 55 to 99.9 parts by mass, the content of polymer B is 0.1 to 35 parts by mass, and the content of the compatibilizer package C 0.1 to 15 parts by mass, with respect to a total of 100 parts by mass of the olefin-based polymer A, the polyhydroxyalkanoate polymer B, and the compatibilizer package C.

[0031] One aspect of certain embodiments of the present invention can be defined by a novel polyhydroxyalkanoate-polypropylene resin composition that can be spun into a fiber alloy having significantly improved moisture absorption and wicking properties compared to conventional polypropylene fibers.

[0032] It is a still further object of embodiments of the present invention to provide a novel polyhydroxyalkanoate-polypropylene fiber alloy material having a compatibilizer additive package.

[0033] It is a still further object of embodiments of the present invention to provide method for producing multi-filament yams using a novel polyhydroxyalkanoatepolypropylene fiber alloy formulation.

[0034] Embodiments of the present invention further provides a novel polyhydroxyalkanoate-polypropylene fiber alloy that offers a sustainable and cost-effective solution for applications requiring enhanced moisture management.74900-0239-706695610.11916

[0035] Also provided herein are methods of fabricating a multi-fiber yam (a) producing an polyhydroxyalkanoate-polypropylene resin composition comprising a polyhydroxyalkanoate, a polypropylene resin, and a compatibilizer package; (b) extruding the polyhydroxyalkanoate-polypropylene resin composition to ensure homogenous dispersion and optimal blending; and (c) melt spinning the polyhydroxyalkanoatepolypropylene resin composition to form a multi-fiber yarn.

[0036] In several embodiments, there is provided for a hydroxyalkanoatepolypropylene fiber alloy comprising a polypropylene, a carbon-negative polyhydroxybutyrate, and a compatibilizer package, wherein said compatibilizer package comprises a polyolefin elastomer and an acrylic acid-propylene copolymer.

[0037] In several embodiments, the polypropylene is from about 65 parts to about 98 parts by mass, said carbon-negative polyhydroxybutyrate is from about 25 parts to about 1 part by mass, and said compatibilizer package is from about 1 to about 10 parts by mass with respect to a total of 100 parts by mass of said polypropylene homopolymer, said carbon-negative polyhydroxybutyrate, and said compatibilizer package.

[0038] In several embodiments, the polypropylene homopolymer is from about 80 parts to about 90 parts by mass, said carbon-negative polyhydroxybutyrate is from about 10 parts to about 2 parts by mass, and said compatibilizer package is from about 2 to about 8 parts by mass with respect to a total of 100 parts by mass of said polypropylene homopolymer, said carbon-negative polyhydroxybutyrate, and said compatibilizer package.

[0039] In several embodiments, the polypropylene homopolymer is from about 85 parts to about 90 parts by mass, said carbon-negative polyhydroxybutyrate is from about 7 parts to about 4 parts by mass, and said compatibilizer package is from about 2 to about 4 parts by mass with respect to a total of 100 parts by mass of said polypropylene homopolymer, said carbon-negative polyhydroxybutyrate, and said compatibilizer package.

[0040] In several embodiments, the polypropylene is a polypropylene homopolymer.

[0041] In several embodiments, the polyolefin elastomer has both metallocene and non-metallocene with elastomeric properties.

[0042] In several embodiments, the hydroxyalkanoate-polypropylene fiber alloy has a vertical wicking rate that is double that of virgin polypropylene. In several84900-0239-706695610.11916embodiments, the hydroxyalkanoate-polypropylene fiber alloy has a moisture absorption rate that is double that of virgin polypropylene.

[0043] Additionally provided for herein is a hydroxyalkanoate-polypropylene fiber alloy comprising a polypropylene, wherein the polypropylene is between about 60 and about 98 parts by mass of a total mass of the alloy, a polyhydroxybutyrate, wherein the polyhydroxybutyrate is between about 1 and about 30 parts by mass of the total mass of the alloy; and a compatibilizer package, wherein the compatibilizer comprises a polyolefin elastomer and an acrylic acid-propylene copolymer, wherein the compatibilizer is between about 1 to about 15 parts by mass of the total mass of the alloy, and wherein the total mass of the alloy is 100 parts by mass.

[0044] In several embodiments, the polyhydroxybutyrate is a carbonnegative polyhydroxybutyrate.

[0045] In several embodiments, the polypropylene homopolymer is between about 60 to about 65 parts by mass, about 65 to about 70 parts by mass, about 70 to about 75 parts by mass, about 75 to about 80 parts by mass, about 80 to about 85 parts, by mass, about 85 to about 90 parts by mass, about 90 to about 95 parts by mass, or any amount between those listed (including endpoints). In several embodiments, the polyhydroxybutyrate is between about 1 to about 2 parts by mass, about 2 to about 3 parts by mass, about 3 to about 4 parts by mass, about 4 to about 5 parts by mass, about 5 to about 6 parts by mass, about 6 to about 7 parts by mass, about 7 to about 8 parts by mass, about 8 to about 9 parts by mass, about 9 to about 10 parts by mass, about 10 to about 11 parts by mass, about 11 to about 12 parts by mass, about 12 to about 13 parts by mass, about 13 to about 14 parts by mass, about 14 to about 15 parts by mass, or any amount between those listed (including endpoints). In several embodiments, the compatibilizer package is between about 1 to about 2 parts by mass, about 2 to about 3 parts by mass, about 3 to about 4 parts by mass, about 4 to about 5 parts by mass, about 5 to about 6 parts by mass, about 6 to about 7 parts by mass, about 7 to about 8 parts by mass, about 8 to about 9 parts by mass, about 9 to about 10 parts by mass, about 10 to about 11 parts by mass, about 11 to about 12 parts by mass, about 12 to about 13 parts by mass, about 13 to about 14 parts by mass, about 14 to about 15 parts by mass, or any amount between those listed (including endpoints).

[0046] In several embodiments, the polypropylene is a polypropylene homopolymer. In several embodiments, the polyolefin elastomer has both metallocene and non-metallocene with elastomeric properties.94900-0239-706695610.11916

[0047] In several embodiments, the alloy is suitable for processing by a meltblown, spunblown, spunbond, injection molding, compression molding, blow molding, rotational molding, extrusion, thermoforming, calendaring, casting, fiber spinning, compounding, or 3D printing process. Combinations or processing are used in some embodiments.

[0048] In several embodiments, the alloy is suitable for processing to generate a non-woven fiber, a multifilament fiber, a monofilament fiber, a stable fiber, a tape yam, or a geotextile.

[0049] In several embodiments, the alloy also includes one or more additional fiber components. In such embodiments, the one or more additional fiber components is selected from the group consisting of natural fibers, regenerated cellulosic fibers, bio-based synthetic fibers, inorganic, carbon and / or metal fiber, aramid fibers, polybenzoxazole fibers, conductive or anti-static fibers, flame-retardant fibers, antimicrobial fibers, superabsorbent fibers and / or bicomponent binder fibers, or combinations thereof.

[0050] The hydroxyalkanoate-polypropylene fiber alloy of Claim 19, wherein the the additional fiber components enhances one or more of the feel, texture, breathability, durability, colorability, stain resistance, odor resistance, sun protection factor or other characteristic of an article manufactured in whole or in part with the alloy comprising the additional fiber(s).

[0051] Also provided for herein, in several embodiments, is a fiber alloy comprising a polyhydroxybutyrate, wherein the polyhydroxybutyrate is between about 1 and about 30 parts by mass of the total mass of the alloy, a non-polyhydroxybutyrate thermoplastic polymer, wherein the non-polyhydroxybutyrate thermoplastic polymer is between about 60 and about 98 parts by mass of a total mass of the alloy and a compatibilizer package, wherein the compatibilizer comprises an elastomer and a copolymer, wherein the compatibilizer is between about 1 to about 15 parts by mass of the total mass of the alloy, and wherein the total mass of the alloy is 100 parts by mass. In several embodiments, the compatibilizer comprises a polyolefin elastomer and an acrylic acid-propylene copolymer.

[0052] In several embodiments, the fiber alloys provided for herein have a vertical wicking rate that is double that of virgin polypropylene. In several embodiments, the fiber alloys provided for herein have a moisture absorption rate that is double that of virgin polypropylene.104900-0239-706695610.11916

[0053] Additional embodiments and features are set forth in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the disclosed embodiments. The features and advantages of the disclosed embodiments may be realized and attained by means of the instrumentalities, combinations, and methods described in the specification.BRIEF DESCRIPTION OF THE DRAWINGS

[0054] A further understanding of the nature and advantages of the disclosed embodiments may be realized by reference to the remaining portions of the specification and the drawings. All drawings are not to scale.

[0055] FIG. 1 is a is a schematic diagram of a prior art fiber line production.

[0056] FIG. 2 is a bar graph comparing the moisture content of the novel polyhydroxyalkanoate-polypropylene alloy fibers according to embodiments of the present invention versus polypropylene virgin fibers based on ASTM D2654 in both forms of loose fiber and knitted fabric.

[0057] FIG. 3 is a photograph comparing the wicking test of the novel polyhydroxyalkanoate-polypropylene alloy fibers according to embodiments of the present invention versus polypropylene virgin fibers based on AATCC TM 197-201 le2(2018) in forms of knitted fabric.

[0058] FIG. 4 is a line graph of vertical wicking rate of the novel polyhydroxyalkanoate-polypropylene alloy fibers according to embodiments of the present invention versus polypropylene virgin fibers based on AATCC TM 197-201 le2(2018) in the form of knitted fabric.

[0059] While the invention is amenable to various modifications, specifics thereof have been shown by way of in the drawings and will be described in detail in the following more detailed description. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

[0060] In the appended figures, similar components and / or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is listed in the114900-0239-706695610.11916specification, the description is applicable to anyone of the similar components having the same first reference label irrespective of the second reference label.DETAILED DESCRIPTION

[0061] Although certain preferred embodiments and examples are disclosed below, the inventive subject matter extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses and to modifications and equivalents thereof. Thus, the scope of the presently disclosed invention is not limited by any of the particular embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding certain embodiments; however, the order of description should not be construed to imply that these operations are order dependent. Additionally, the structures, systems, and / or devices described herein may be embodied as integrated components or as separate components. For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not necessarily all such aspects or advantages are achieved by any particular embodiment. Thus, for example, various embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other aspects or advantages as may also be taught or suggested herein.

[0062] Certain non-limiting embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the devices and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present technology.

[0063] The present specification generally relates to a polyhydroxyalkanoate-polypropylene resin composition comprising an olefin-based polymer A, a polyhydroxyalkanoate polymer B, and a compatibilizer package C, wherein 124900-0239-706695610.11916the polymer A is selected from the group consisting of an ethylene-based polymer, a propylene-based polymer, and a butene-based polymer, and may be a combination of any two or more thereof, wherein the polymer B is a poly(hydroxyalkanoate)-based polymer having a melting point of 100 °C to 220 °C, wherein the compatibilizer package C is an additive comprising an acrylic acid-propylene copolymer and a polyolefin elastomer or a combination of both, and the content of the polymer A is 55 to 99.7 parts by mass, the content of polymer B is 0.1 to 35 parts by mass, and the content of the compatibilizer package is C 0.1 to 15 parts by mass, with respect to a total of 100 parts by mass of the olefin-based polymer A, the polyhydroxyalkanoate polymer B, and the compatibilizer package C. The resulting polyhydroxyalkanoate-polypropylene composition comprising a polyhydroxyalkanoate, a polypropylene resin, and a compatibilizer package; (b) extruding the polyhydroxyalkanoate-polypropylene polypropylene alloy composition to ensure homogenous dispersion and optimal blending; (c) drying and pelleting the extruded polyhydroxyalkanoate-polypropylene resin composition; and (d) melt spinning the pelleted polyhydroxyalkanoate-polypropylene resin composition to form a multi-fiber yam

[0064] The resultant textile demonstrates both a superior wicking speed and moisture absorption capacity having a rate approximately double that of virgin polypropylene fabric.Polymer A

[0065] The propylene-based copolymer is a polymer containing 55% by mass or more of a structural unit derived from propylene with respect to a total of 100 parts by mass of the polyhydroxyalkanoate-polypropylene resin composition, and examples thereof include a propylene homopolymer, a propylene-ethylene copolymer, a propylene-1-butene copolymer, a propylene- 1 -hexene copolymer, a propyl ene-1 -octene copolymer, a propylene- ethyl ene-1 -butene copolymer, a propylene-ethylene- 1 -hexene copolymer, and a propylene-ethylene- 1 -octene copolymer. The propylene-based copolymer may be a combination of two or more propylene-based copolymers. It is preferable that the olefin-based polymer A is a propylene-based copolymer.

[0066] The ethylene-based copolymer is a polymer containing 55% by mass or more of a structural unit derived from ethylene, and examples thereof include an ethylene homopolymer, an ethylene- 1 -butene copolymer, an ethylene- 1 -hexene copolymer, an ethylene- 1 -octene copolymer, and an ethylene- 1 -butene- 1 -hexene copolymer. The134900-0239-706695610.11916ethylene-based copolymer may be a combination of two or more ethylene-based copolymers.

[0067] The butene-based copolymer is a polymer containing 55% by mass or more of a structural unit derived from 1 -butene, and examples thereof include a 1 -butene homopolymer, a 1-butene-ethylene copolymer, a 1-butene-propylene copolymer, a 1-butene-1 -hexene copolymer, a 1 -butene- 1 -octene copolymer, a 1-butene-ethylene-propylene copolymer, a 1-butene-ethylene- 1 -hexene copolymer, a 1-butene-ethylene- 1-octene copolymer, a 1-butene-propylene- 1 -hexene copolymer, and a 1-butene-propylene-1 -octene copolymer. The butene-based copolymer may be a combination of two or more types of butene-based copolymers.

[0068] The olefin-based polymer A may be one type of polymer or a mixture of two or more types of polymers.

[0069] The melt mass flow rate (MFR) of the olefin-based polymer A measured in accordance with ASTM DI 238 under conditions of a temperature of 230°C and a load of 2.16 kgf is preferably 0.1 g / 10 minutes or more and 200 g / 10 minutes or less.

[0070] The melting point of the olefin-based polymer A may be 110 to 180° C.

[0071] The above-mentioned olefin-based polymer A can be produced by a known polymerization method using a known polymerization catalyst.

[0072] The olefin-based polymer A is preferably a propylene homopolymer. The propylene homopolymer is a polymer composed of only constitutional units derived from propylene.

[0073] The melt mass flow rate of the propylene homopolymer measured under conditions of a temperature of 230° C and a load of 2. 16 kgf may be 0.1 g / 10 minutes or more, 1 g / 10 minutes or more, 3 g / 10 minutes or more, or 5 g / 10 minutes or more from the viewpoint of processability. The melt mass flow rate can be 80 g / 10 minutes or less, 60 g / 10 minutes or less, 50 g / 10 minutes or less, 30 g / 10 minutes or less, 20 g / 10 minutes or less. The melt mass flow rate of the propylene homopolymer is determined in accordance with ASTM DI 238.

[0074] The propylene homopolymer can be produced by a known polymerization method using a catalyst system formed by contacting a known solid titanium catalyst, an organometallic compound catalyst, and optionally an electron-donor; a catalyst system formed by contacting a cyclopentadienyl ring-containing transition metal compound of the fourth group of the periodic table and an alkylaluminoxane; and a catalyst 144900-0239-706695610.11916system formed by contacting a cyclopentadienyl ring-containing transition metal compound of the fourth group of the periodic table, a compound that reacts with the transition metal compound to form an ionic complex, and an organoaluminum compound.

[0075] In one embodiment the olefin-based polymer A is a polypropylene homopolymer containing 5% to 99.9%, 5% to 98% by mass of the polyhydroxyalkanoatepolypropylene resin composition, or more preferably 80% to 99.9%. In one embodiment, it has a polypropylene homopolymer of 70% to 92 % by mass, more preferably 85% to 90%. In one embodiment a thermoplastic polymer is present in an amount ranging from about 80% to about 99.9%.

[0076] Depending on the embodiments, other synthetic fibers are used in place of, or in addition to, a propylene homopolymer. In several embodiments, an additional synthetic fiber is selected from polyester (e.g., polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate), polyamides (also referred to as nylon, e.g., PA6, PA66, PA11, PA12), acrylics (e.g., polyacrylonitrile) or modacrylics, polyethylene (e.g., high-density polyethylene or ultra high molecular weight polyethylene), elastomers (e.g., spandex or elastane, or thermoplastic polyurethane), polyvinyl alcohol, polyvinyl chloride or other chlorofibers, polytetrafluoroethylene (PTFE), polyphenylene sulfide (PPS), liquid crystal polymer (LCP), polyimide (PI), polyetherimide (PEI), polyether ether ketone (PEEK), polyvinylidene fluoride (PVDF) or combinations thereof.Polymer B

[0077] According to several embodiments, the polymer B is a poly(hydroxyalkanoate)-based polymer (“PHA”) is a containing 30% by mass or less (with respect to a total of 100 parts by mass of the polyhydroxyalkanoate-polypropylene resin composition) having a melting point of 100 to 220° C. It is to be understood that throughout this specification when PHA is referred to it is contemplated that this term includes homopolymers, random co-polymers, impact co-polymers and blends thereof. As used herein, the terms “functional properties” and “functional characteristics” shall be given their ordinary meanings and shall also refer to the specification, features, qualities, traits, or attributes of a material, including of a PHA or other materials. The functional characteristics of a PHA include, but are not limited to molecular weight, poly dispersity and / or poly dispersity index, melt flow and / or melt index, monomer composition, copolymer structure, melt index, non-PHA material concentration, purity, impact strength, density, specific viscosity, viscosity resistance, acid resistance, mechanical shear strength,154900-0239-706695610.11916flexural modulus, elongation at break, freeze-thaw stability, processing conditions tolerance, shelf-life / stability, hygroscopicity, and color. As used herein, the term “poly dispersity index” (or PDI), shall be given its ordinary meaning and shall be considered a measure of the distribution of molecular mass of a given polymer sample (calculated as the weight average molecular weight divided by the number average molecular weight).

[0078] Polyhydroxyalkanoates are biological polyesters synthesized by a broad range of natural and genetically engineered microorganisms and microorganism enzymes as well as genetically engineered plant crops (Braunegg, et al., 1998, J. Biotechnology 65:127-161; Madison and Huisman, 1999, Microbiology and Molecular Biology Reviews, 63:21-53; Poirier, 2002, Progress in Lipid Research 41:131-155). These polymers are biodegradable thermoplastic materials, can be produced from renewable resources, and have the potential for use in a broad range of industrial applications (Williams & Peoples, CHEMTECH 26:38-44 (1996)). Useful microbial strains for producing PHAs, include Cupriavidus necator (formerly known as Wautersia eutropha, Alcaligenes eutrophus (renamed as Ralstonia eutropha)), Alcaligenes latus, Aeromonas, Comamonas, Bacillus megaterium, Bacillus cereus SPV, Sinorhizobium meliloti, Azotobacter spp, Pseudomonas, and Methylosinus, spp Metylobacterium spp, and Methylococcus spp and genetically engineered organisms of the above-mentioned microbes.

[0079] In general, a PHA is formed by enzymatic polymerization of one or more monomer units. Over 100 different types of monomers have been incorporated into the PHA polymers (Steinbuchel and Valentin, FEMS Microbiol. Lett., 128:219-228 (1995). Examples of monomer units incorporated in PHAs include 2-hydroxybutyrate, lactic acid, glycolic acid, 3-hydroxybutyrate (hereinafter referred to as 3HB), 3 -hydroxypropionate (hereinafter referred to as 3HP), 3 -hydroxy valerate (hereinafter referred to as 3HV), 3-hydroxyhexanoate (hereinafter referred to as 3HH), 3-hydroxyheptanoate (hereinafter referred to as 3HHep), 3 -hydroxy octanoate (hereinafter referred to as 3HO), 3-hydroxynonanoate (hereinafter referred to as 3HN), 3 -hydroxy decanoate (hereinafter referred to as 3HD), 3 -hydroxy dodecanoate (hereinafter referred to as 3HDd), 4-hydroxybutyrate (hereinafter referred to as 4HB), 4-hydroxyvalerate (hereinafter referred to as 4HV), 5 -hydroxy valerate (hereinafter referred to as 5HV), and 6-hydroxyhexanoate (hereinafter referred to as 6HH). 3-hydroxyacid monomers incorporated into PHAs are the (D) or (R) 3-hydroxyacid isomer with the exception of 3HP which does not have a chiral center.164900-0239-706695610.11916

[0080] The terms “PHA,” “PHAs,” and “polyhydroxyalkanoate,” as used herein, shall be given their ordinary meaning and shall include, but not be limited to, polymers generated by microorganisms or microorganism enzymes; biodegradable and / or biocompatible polymers that can be used as alternatives to petrochemical-based plastics such as polypropylene, polyethylene, and polystyrene; polymers produced by bacterial fermentation of sugars, lipids, or gases; thermoplastic or elastomeric materials derived from microorganisms or microorganism-derived enzymes; and / or polymers generated by chemical reaction not inside of microbial cell walls. PHAs include, but are not limited to, polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), polyhydroxybutyrate-covalerate (PHBV), polyhydroxyhexanoate (PHHx) and blends thereof as discussed in detail below, as well as both short chain length (SCL), medium chain length (MCL), and long chain length (LCL) PHAs.

[0081] In some embodiments, the PHA is a homopolymer (all monomer units are the same). Examples of PHA homopolymers include poly 3 -hydroxy alkanoates (e.g., poly 3 -hydroxypropionate (hereinafter referred to as P3HP), poly 3 -hydroxybutyrate (hereinafter referred to as PHB) and poly 3 -hydroxy valerate), poly 4-hydroxyalkanoates (e.g., poly 4-hydroxybutyrate (hereinafter referred to as P4HB), or poly 4-hydroxyvalerate (hereinafter referred to as P4HV)) and poly 5 -hydroxy alkanoates (e.g., poly 5-hydroxyvalerate (hereinafter referred to as P5HV)).

[0082] In certain embodiments, the starting PHA is a copolymer (containing two or more different monomer units) in which the different monomers are randomly distributed in the polymer chain. Examples of PHA copolymers include poly 3-hydroxybutyrate-co-3 -hydroxypropionate (hereinafter referred to as PHB3HP), poly 3-hydroxybutyrate-co-4-hydroxybutyrate (hereinafter referred to as PHB4HB), poly 3-hydroxybutyrate-co-4-hydroxy valerate (hereinafter referred to as PHB4HV), poly 3-hydroxybutyrate-co-3 -hydroxy valerate (hereinafter referred to as PHB3HV), poly 3-hydroxybutyrate-co-3-hydroxyhexanoate (hereinafter referred to as PHB3HH), poly 3-hydroxybutyrate-co-3 -hydroxy valerate-co-3 -hydroxyhexanoate (hereinafter referred to as PHB3HV3HH), poly 3-hydroxybutyrate-co-4-hydroxyvalerate (hereinafter referred to as PHB4HV) and poly 3-hydroxybutyrate-co-5-hydroxyvalerate (hereinafter referred to as PHB5HV).

[0083] By selecting the monomer types and controlling the ratios of the monomer units in a given PHA copolymer a wide range of material properties can be achieved. Although examples of PHA copolymers having two different monomer units 174900-0239-706695610.11916have been provided, the PHA can have more than two different monomer units (e.g., three different monomer units, four different monomer units, five different monomer units, six different monomer units). An example of a PHA having 4 different monomer units would be PHB-co-3HH-co-3HO-co-3HD or PHB-co-3-HO-co-3HD-co-3HDd (these types of PHA copolymers are hereinafter referred to as PHB3HX). Typically, where the PHB3HX has 3 or more monomer units the 3HB monomer is at least 70% by weight of the total monomers, preferably 85% by weight of the total monomers, most preferably greater than 90% by weight of the total monomers for example 92%, 93%, 94%, 95%, 96% by weight of the copolymer and the HX comprises one or more monomers selected from 3HH, 3HO, 3 HD, 3HDd.

[0084] The homopolymer (where all monomer units are identical) PHB and 3 -hydroxybutyrate copolymers (PHB3HP, PHB4HB, PHB3HV, PHB4HV, PHB5HV, PHB3HHP, hereinafter referred to as PHB copolymers) containing 3 -hydroxybutyrate and at least one other monomer are of particular interest for commercial production and applications. It is useful to describe these copolymers by reference to their material properties as follows. Type 1 PHB copolymers typically have a glass transition temperature (Tg) in the range of 6°C to -10°C, and a melting temperature (TM) of between 80°C to 180°C. Type 2 PHB copolymers typically have a Tg of -20°C to -50°C and TM of 55°C to 90°C and are based on PHB4HB, PHB5HV polymers with more than 15% 4HB, SHV, 6HH content or blends thereof. In particular embodiments, the Type 2 copolymer have a phase component with a Tg of -15°C to -45 °C and no TM.

[0085] As used in the present invention, the molecular weight of PHA ranges between about 5,000,000 and about 2,500,000 Daltons, between about 2,500,000 and about 1,000,000 Daltons, between about 1,000,000 and about 750,000 Daltons, between about 750,000 and about 500,000 Daltons, between about 500,000 and about 250,000 Daltons, between about 250,000 and about 100,000 Daltons, between about 100,000 and about 50,000 Daltons, between about 50,000 and about 10,000 Daltons, and overlapping ranges thereof.

[0086] In determining the molecular weight, techniques such as gel permeation chromatography (GPC) can be used. In the methodology, a polystyrene standard is utilized. The PHA can have a polystyrene equivalent weight average molecular weight (in Daltons) of at least 500, at least 10,000, or at least 50,000 and / or less than 2,000,000, less than 1,000,000, less than 1,500,000, and less than 800,000. In certain embodiments, preferably, the PHAs generally have a weight-average molecular weight in 184900-0239-706695610.11916the range of 100,000 to 700,000. For example, the molecular weight range for PHB and Type 1 PHB copolymers for use in this application are in the range of 200,000 Daltons to 1.5 million Daltons as determined by GPC method and the molecular weight range for Type 2 PHB copolymers for use in the application 20,000 to 1.5 million Daltons.

[0087] In certain embodiments, the branched PHA, as discussed in further detail below, can have a linear equivalent weight average molecular weight of from about 150,000 Daltons to about 500,000 Daltons and a poly dispersity index of from about 1.0 to about 8.0. As used herein, weight average molecular weight and linear equivalent weight average molecular weight are determined by gel permeation chromatography, using, e.g., chloroform as both the eluent and diluent for the PHA samples. Calibration curves for determining molecular weights are generated using linear polystyrenes as molecular weight standards and a “log MW vs. elution volume” calibration method.

[0088] PHAs for use in the methods and compositions described in this invention are selected from PHB; a PHA blend of PHB with a Type 1 PHB copolymer where the PHB content by weight of PHA in the PHA blend is in the range of 5% to 95% by weight of the PHA in the PHA blend; a PHA blend of PHB with a Type 2 PHB copolymer where the PHB content by weight of the PHA in the PHA blend is in the range of 5% to 95% by weight of the PHA in the PHA blend; a PHA blend of a Type 1 PHB copolymer with a different Type 1 PHB copolymer and where the content of the first Type 1 PHB copolymer is in the range of 5% to 95% by weight of the PHA in the PHA blend; a PHA blend of a Type 1 PHB copolymer with a Type 2 PHA copolymer where the content of the Type 1 PHB copolymer is in the range of 30% to 95% by weight of the PHA in the PHA blend; a PHA blend of PHB with a Type 1 PHB copolymer and a Type 2 PHB copolymer where the PHB content is in the range of 10% to 90% by weight of the PHA in the PHA blend, where the Type 1 PHB copolymer content is in the range of 5% to 90% by weight of the PHA in the PHA blend and where the Type 2 PHB copolymer content is in the range of 5% to 90% by weight of the PHA in the PHA blend.

[0089] The melt mass flow rate (MFR (B)) of the polymer B measured under conditions of a temperature of 190° C and a load of 2. 16 kgf in accordance with ASTM D1238 is preferably 0.1 g / 10 min or more and 200 g / 10 min or less. The MFR (B) may be 1 g / 10 min or more, 3 g / 10 min or more, or 5 g / 10 min or more. The MFR (B) may be 7 g / 10 min or more, 8 g / 10 min or more, 10 g / 10 min or more, or 20 g / 10 min or more. MFR (B) may be 150 g / 10 min or less or may be 100 g / 10 min or less.194900-0239-706695610.11916

[0090] The melting point (Tm) of the polymer B is 100° C or higher, and may be 135° C or higher, 145° C or higher, 150° C or higher, 155° C or higher, 160° C or higher, 165° C or higher, 170° C or higher, or 175° C or higher. The melting point (Tm) of the polymer B is 220° C or lower, may be 210° C or lower, may be 200° C or lower, or may be 190° C or lower.

[0091] In one embodiment the PHA is a carbon-negative PHB containing 35% to 0.1% by mass of the polyhydroxyalkanoate-polypropylene resin composition, and more preferably, 25% to 1%, and more preferably 15% to 2%. In one embodiment, it has a carbon-negative PHB of 10% to 2% by mass, more preferably 7% to 4%.Compatibilizer Package C

[0092] Compatibilizer package C is an additive containing less than 15% per mass (less than 10% in some embodiments) with respect to a total of 100 parts by mass of the polyhydroxyalkanoate-polypropylene resin composition and examples thereof include an acid group-containing polyolefins. The acid functionality may be derived from but not limited to the copolymerization of one or more ethylenically unsaturated monomers having one or more acid functional groups, such as carboxyl groups. Non-limiting examples of acid-functional ethylenically unsaturated monomers include, for example, methacrylic acid and acrylic acid. Thus, the polyolefin component may comprise an acrylic resin, which may be obtained by copolymerization of at least one or more olefin monomers with (meth) acrylic acid and / or derivatives thereof such as (meth) acrylate monomers. As used herein, the terms “(meth) acrylic acid”, “(meth) acrylate”, and the like collectively refer to acrylic acid and methacrylic acid, or acrylate and methacrylate, respectively. An example of an acid functional polyolefin is an ethylene acrylic acid copolymer. Such copolymers are commercially available from Dow’s PRIMACOR product line. Also, acidcontaining polyolefin can be but not limited to, acrylic acid-propylene copolymer acid anhydride group-containing polyolefins obtained by random copolymerization or graft copolymerization of maleic anhydride; carboxylic acid group-containing polyolefins obtained by random copolymerization or graft copolymerization of unsaturated carboxylic acids such as (meth)acrylic acid; containing polyolefin; epoxy group-containing polyolefin obtained by random copolymerization or graft copolymerization of glycidyl (meth)acrylate, and the like and a polyolefin.

[0093] Examples of the acid group-containing polyolefin used in the present invention include the following: maleic anhydride-modified polypropylene, maleic 204900-0239-706695610.11916anhydride-modified polyethylene, acrylic acid-modified polypropylene, ethylene / methacrylic acid random copolymer, ethylene / glycidyl methacrylate random copolymer, or glycidyl methacrylate-modified polypropylene. Ethylene-maleic anhydride copolymer, ethylene-ethyl acrylate-maleic anhydride copolymer, ethylene-unsaturated carboxylic acid copolymer (for example, ethylene-methacrylic acid copolymer, ethyleneacrylic acid copolymer), a copolymer of ethylene and acrylic acid or methacrylic acid, an ethylene-glycidyl methacrylate copolymer, an ethylene-vinyl acetate-glycidyl methacrylate copolymer. Examples thereof include ethylene-methyl acrylate-glycidyl methacrylate copolymer, propylene-maleic anhydride copolymer, propylene-unsaturated carboxylic acid copolymer, etc. These carboxylic acid, acid anhydride, glycidyl methacrylate content is 1 ~ 10% by mass, polyolefin elastomer content of 1-5% by mass is preferred. Graft modified polyolefins can also be used. Specifically, maleic anhydride-modified polypropylene, maleic anhydride-modified polyethylene, maleic anhydride-modified ethylene-ethyl acrylate copolymer, polyolefin-vinyl polymer graft copolymer, and ethylene-propylene rubber grafted with glycidyl methacrylate. Examples of such a copolymer can be given. Examples of the acid-modified polypropylene include Polybond 100 IN, Polybond 1002 (manufactured by SI Group).

[0094] Compatibilizer package C used in this invention could have a polyolefin elastomer, such as, but not limited to, “Polypropylene-Based Polyolefin Elastomer” (“POE”) is a propylene-based copolymer of both metallocene and nonmetallocene with elastomeric properties. Non-limiting examples of propylene-based polyolefin elastomers are those polymers commercially available under the trade names THERMORUN™ and ZELAS™ (non-metallocene) from Mitsubishi Chemical Corporation, ADFLEX™ and SOFTELL™ (both non-metallocene) from LyondellBasell, VERSIFY™ (metallocene) from the Dow Chemical Company and VISTAMAXX™ (metallocene) from ExxonMobil. Polypropylene-based thermoplastic polyolefin blend (“TPO”) is polypropylene, polypropyleneethylene copolymer, metallocene homopolypropylene, and metallocene polypropylene-ethylene copolymer, having ethylene-propylene copolymer rubber in quantities large enough to give the mixture of thermoplastic polyolefins plastomeric, elastoplastomeric or elastomeric properties. Nonlimiting examples of polypropylene-based polyolefin blend polymers are those polymer blends commercially available under the trade names EXCELINK™ from JSR Corporation, THERMORUN™ and ZELAS™ from Mitsubishi Chemical Corporation, FERROFLEX™ and RxLOY™ from Ferro Corporation, and TELCAR™ from Teknor 214900-0239-706695610.11916Apex Company. Polypropylene-based thermoplastic elastomer blend (“TPE”) is polypropylene, polypropylene ethylene copolymer, metallocene homopolypropylene and metallocene polypropylene-ethylene copolymer, having diblock or multiblock thermoplastic rubber modifiers (S and BS, SEPS, SEEPS, SEP, SERC, CEBC, HSB, SBS, SIS, SEBS, and the like) in amounts large enough to give the blend of thermoplastic elastomers plastomeric, elastoplastomeric or elastomeric properties. Non-limiting examples of polypropylene-based thermoplastic elastomer blend polymers are those polymer blends commercially available under the trade name DYNAFLEX® and VERSAFLEX® from GLS Corporation, MONPRENE® and TEKRON® from Teknor Apex Company, and DURAGRIP® from Advanced Polymers. Alloys (a division of Ferro Corporation).

[0095] The compatibilizer package C used in the present invention has a polyolefin elastomer content of 0.1% to 10% by mass, and more preferably, 2 to 4% by mass and a polyolefin having a content of 0 to 5%, and more preferably, 2 to 4% by mass. In one embodiment, the compatibilizer package C content is 3 to 7% comprising polyolefin elastomer content of 2 to 4% in combination with a polyolefin content of 1 to 3% by mass.

[0096] The hydroxyalkanoate-polypropylene resin composition of the present invention is formed by blending PHB (and preferentially, Aircarbon® PHB made by Newlight Technologies, Inc., a carbon-negative polymer made from greenhouse gas that can be used to make carbon-captured resin, having a carbon footprint in the range of 150 -300Kg CO2e / Kg of carbon captured resin) with polypropylene in the presence of a compatibilizer additive package. This mixture is then compounded using an extruder, such as but not limited to a twin-screw extruder at a temperature in the range of 150°C to 300°C, and more preferably 170°C to 280°C, to ensure homogenous dispersion and optimal blending. The carbon-captured resin composition extruded via a strand die into a water bath and pelletized and dried.

[0097] Synthetic fibers can be produced using several processes, each suited to specific polymers and applications. Melt spinning, the most common method, melts the polymer and extrudes it through a spinneret, cooling it into solid fibers. Wet spinning and dry spinning are used for heat-sensitive polymers, with fibers solidified in a coagulation bath or through solvent evaporation. Gel spinning produces ultra-strong fibers by stretching polymer gels, while electrospinning creates nanofibers using high electric fields. Other techniques like film splitting, bi-component spinning, and flash spinning cater to224900-0239-706695610.11916specialized needs, offering unique fiber properties. The choice of process depends on the polymer's thermal stability, solvent compatibility, and desired fiber characteristics.

[0098] The hydroxyalkanoate-polypropylene resin composition is preferably melt spun into a multi-fiber yam. In this preferred embodiment melt spinning is a widely used process for manufacturing synthetic fibers from thermoplastic polymers like polypropylene, polyester, and nylon. Referring to Figure 1, the process begins by heating the polymer above its melting point to form a viscous melt. This molten polymer is then forced through a spinneret, a device containing numerous small holes, which determines the diameter and shape of the fibers. The spinneret plays a crucial role in the process, as its design and hole geometry directly influence the properties and final appearance of the fibers. Once the polymer emerges from the spinneret as continuous filaments, it undergoes a cooling process, typically achieved using a controlled stream of air to solidify the fibers. The solidified filaments are then passed over godets, which are rotating rollers that apply tension to draw and align the polymer chains. This drawing process enhances the fiber's tensile strength, reduces its diameter, and improves its mechanical properties.

[0099] After drawing, the fibers are guided to a winder, which collects the continuous filaments onto spools or bobbins for storage and further processing. The winder operates at a carefully controlled speed to ensure uniformity and prevent damage to the fibers during collection. Melt spinning, as one non-limiting example of processing, offers several advantages, including cost-effectiveness, high production speed, and the absence of solvents, making it an environmentally friendly method. However, it is limited to thermoplastic polymers that can withstand high processing temperatures without degradation. Applications of melt-spun fibers include textiles, medical products, geotextiles, and industrial materials.Additional Fiber Components[000100] While several embodiments relate to an alloy comprising polymer A, polymer B, and compatibilizer C, in additional embodiments, additional fiber components are also included.[000101] For example, in some embodiments, in addition to the hydroxyalkanoate-polymer resin, the alloy further comprises one or more natural fibers. In some embodiments, the natural fibers are selected from cotton, wool (e.g., sheep wool), specialty animal fibers (e.g., cashmere, alpaca, mohair), silk, flax / linen, hemp, jute, ramie,234900-0239-706695610.11916kenaf (or other bast fiber), leaf fibers (such as sisal and / or abaca), and seed or fruit fibers, such as kapok and / or coir), or combinations thereof.[000102] In several embodiments, the alloy further comprises one or more regenerated cellulosic fibers. In several embodiments, the regenerated cellulosic fibers are selected from rayon (e.g., viscose rayon), modal, lyocell (also referred to as Tencel), cellulose acetate, cellulose triacetate, or combinations thereof.[000103] In several embodiments, the alloy further comprises one or more bio-based synthetic fiber. For example, in several embodiments, the bio-based synthetic fiber is selected from polylactic acid (PLA), polybutylene succinate (PBS), polybutylene adipate terephthalate (PB AT), or combinations thereof.[000104] In several embodiments, the alloy further comprises one or more inorganic, carbon and / or metal fiber. For example, in some embodiments, the alloy includes one or more glass fibers (e.g., E-glass or S-glass), basalt fibers, carbon fibers (e.g., polyacrylonitrile carbon fiber or pitch-based carbon fibers), ceramic fibers (e.g., alumina, silica), metal fibers, or in some cases, boron fibers, or combinations thereof.[000105] In several embodiments, the alloy further comprises one or more “high-performance” or “specialty” fiber. For example, in some embodiments, the alloy further comprises one or more aramid fiber (e.g., para-aramid or meta-aramid), polybenzoxazole, conductive or anti-static fibers, flame-retardant fibers, antimicrobial fibers, superabsorbent fibers and / or bicomponent binder fibers, or combinations thereof.[000106] In several embodiments, the additional fiber components enhances one or more of the feel, texture, breathability, durability, colorability, stain resistance, odor resistance, sun protection factor or other characteristic of an article manufactured in whole or in part with the alloy comprising the additional fiber(s).Hydrolytic Stability of PLA Using PHA Additives and Blends[000107] In certain embodiments, polyhydroxyalkanoate materials are used in combination with polylactic acid (“PLA”) to improve, for example, the hydrolytic stability of PLA-containing compositions. As used herein, “hydrolytic stability” shall be given its ordinary meaning and shall refer to resistance to hydrolysis and / or moisture-induced degradation of PLA. In several embodiments, the improved PLA hydrolytic stability is recognized by observation of, for example, reduced molecular weight loss of PLA over time under humid and / or aqueous conditions. In several embodiments, the improved PLA hydrolytic stability is recognized by observation of reduced loss of mechanical properties 244900-0239-706695610.11916(e.g., tensile strength, elongation, impact resistance, modulus). In several embodiments, the improved PLA hydrolytic stability is recognized by observation of reduced embrittlement, cracking, crazing, or stress whitening. In several embodiments, the improved PLA hydrolytic stability is recognized by observation of reduced increase in melt flow index (MFI) or reduction in intrinsic viscosity. In several embodiments, the improved PLA hydrolytic stability is recognized by observation of reduced generation of lactic acid oligomers or other degradation products, as compared to an otherwise identical PLA composition lacking the PHA component. Combinations of any of the foregoing improvements occur in some embodiments.[000108] According to several embodiments, PHA improves hydrolytic stability of PLA by modifying the microstructure of the PLA phase to reduce water uptake pathways and / or reduce hydrolysis-prone amorphous regions. According to several embodiments, PHA improves hydrolytic stability of PLA by increasing crystallinity and / or altering crystallite size / distribution. According to several embodiments, PHA improves hydrolytic stability of PLA by forming a dispersed morphology that reduces diffusion of water into the PLA phase. According to several embodiments, PHA improves hydrolytic stability of PLA by reacting with, neutralizing, or otherwise reducing the concentration of hydrolysis-promoting species (e.g., residual catalysts, acidic species, moisture). According to several embodiments, PHA improves hydrolytic stability of PLA by enabling incorporation of hydrolysis-stabilizing additives with improved dispersion and / or retention in the PLA matrix. Combinations of any of the foregoing mechanisms of action occur.[000109] In various embodiments, the PHA comprises one or more of PHB, PHBV, P(3HB-co-3HHx), P(3HB-co-4HB), or blends thereof. The PHA may be a virgin PHA, recycled PHA, or modified PHA (e.g., end-capped, grafted, or chain-extended). The PLA may be any commercially available PLA grade, including neat PLA, impact-modified PLA, nucleated PLA, or PLA copolymers. The PHA may be present in an amount effective to increase hydrolytic stability, for example about 0.1 wt% to about 50 wt% of the total polymeric composition, including ranges such as 0.5-20 wt%, 1-15 wt%, or 2-10 wt%, depending on the target application.[000110] In some embodiments, the PLA / PHA composition further includes one or more compatibilizers and / or reactive modifiers. In several embodiments, a compatibilizer and / or reactive modifier is configured to improve interfacial adhesion and / or phase morphology, including epoxy-functional chain extenders, multifunctional anhydrides, isocyanates, carbodiimides, oxazolines, or peroxide-based grafting systems. In 254900-0239-706695610.11916some embodiments, such reactive modifiers reduce hydrolysis-driven molecular weight loss by consuming carboxyl and / or hydroxyl end groups and / or by increasing molecular weight and / or branching.[000111] In some embodiments, the composition further includes hydrolysis stabilizers. In several embodiments, hydrolysis stabilizers include, but are not limited to, carbodiimide-based hydrolysis stabilizers, acid scavengers, moisture scavengers, basic fillers, hydrophobic waxes, barrier additives, or combinations thereof. In certain embodiments, PHA synergistically improves the effectiveness of such stabilizers by improving dispersion, immobilization, and / or retention within the PLA matrix during processing and end use.[000112] As discussed in more detail below, PLA / PHA compositions may be compounded, pelletized, and formed into articles by extrusion, injection molding, thermoforming, blow molding, fiber spinning, film casting, or additive manufacturing. In some embodiments, the improved hydrolytic stability enables use of PLA-based articles in higher humidity environments, repeated washing, hot-fill exposure, refrigerated or frozen storage, and / or extended shelf-life applications, while maintaining mechanical performance and processability.Fiber Forms, Production, and Processing[000113] There are a variety of forms of fibers that are generated from the hydroxyalkanoate-polypropylene fiber alloys provided for herein. In several embodiments, the fibers are monofilaments. In several embodiments, the fibers are multifilament. In several embodiments, the fibers are staple fibers. In several embodiments, the fibers are tow fibers (e.g., filament bundles). In several embodiments, the fibers are tape fibers, also known as tape yarn or film yarn), such as split-film or fibrillated fibers. In several embodiments, the fibers are yams, such as false-twist or air-textured yam. In several embodiments, the fibers are bicomponent fibers (such as core-sheath, side-by-side fibers, or “islands in the sea” fibers).[000114] There are a variety of ways by which fibers are generated from the hydroxyalkanoate-polypropylene fiber alloys provided for herein. For example, in several embodiments, the alloy is produced by combining two polymers (e.g., a polyhydroxyalkanoate polymer with a polypropylene polymer) using a compatibilizer additive and melt-spinning the resulting composition into multi-filament yarns, fibers, and non-woven fabrics.264900-0239-706695610.11916[000115] In several embodiments, the alloy is processed using a meltblown procedure. In several embodiments, the alloy is processed using a spunbond procedure. In several embodiments, the alloy is processed to generate a woven fiber. In several embodiments, the alloy is processed by a melt-spun procedure. In several embodiments, a combination of spunbond-meltblown processing is used. In several embodiments, the alloy is processed using a needlepunch procedure. In several embodiments, the alloy is processed using a thermal bonding procedure. In several embodiments, the alloy is processed using a hydroentanglement procedure (e.g., spunlace). In several embodiments, the alloy is processed using an air-laid or wet-laid procedure.[000116] In several embodiments, the alloy is processed to form a geotextile, geogrid, geomembrane-reinforced composite, or geonet. In several embodiments, these geotextiles are extruded, woven, needlepunched nonwoven, heat-bonded, knitted, or any combination of such processes, depending on the embodiment.[000117] According to several embodiments, the alloys provided herein are carbon neutral (e.g., their production produces an equivalent or substantially equivalent carbon-dioxide equivalent (CO2e) as the carbon dioxide sequestered from the environment in the alloys). In several embodiments, the alloys provided for herein are carbon-negative (e.g., their production contributes to more carbon-dioxide equivalent greenhouse gas (CO2e) mbeing removed from the air than emitted. Thus, in several embodiments, the production of alloys reduces CO2e by sequestering more carbon in the alloy than is generated in the production of the alloy, resulting in improvements to the environment.[000118] The following non-limiting examples provide methods for preparing a novel carbon-captured polypropylene fiber alloy with significantly improved moisture absorption and wicking properties compared to conventional polypropylene fibers. All scientific and technical terms have the meanings as understood by one with ordinary skill in the art. The specific examples which follow illustrate the representative carbon-captured polypropylene fiber alloys that are capable of being achieved by the present invention and are not to be construed as limiting the invention in sphere or scope. The methods may be adapted in order to produce compositions embraced by this invention but not specifically disclosed. Further variations of the methods to produce the same compositions in somewhat different fashion will be evident to one skilled in the art.ExampleMaterials274900-0239-706695610.11916[000119] In this nonlimiting example, a hydroxyalkanoate-polypropylene resin was formed by uniformly mixing in a powder state 89% by mass of the Polymer A, 4% by mass of the Polymer B, and 7% by mass of the Compatibilizer package C comprising 3% by mass polyolefin elastomer (Vistamaxx 7050BF) and 4% by mass acrylic acid-propylene copolymer (Polybond 100 IN), and then feeding the mixture into fed into an 18mm-diameter twin-screw extruder at temperature profile of 160°C to 190°C, having a screw rotation of 200 rpm. The hydroxyalkanoate-polypropylene resin composition extruded via a strand die into a water bath and pelletized and dried.Melt Spinning Procedure[000120] Reference polypropylene (Exxon PP3155) and the hydroxyalkanoate-polypropylene resin composition of the present invention was converted to multi-filament yams through melt-spinning system as discussed previously and shown in Figure 1. An FET (Fiber Extrusion Technologies, Limited) spinning-drawing-winding machine (M93) has been used with settings specifically for each material. The extruder with screw diameter of 32 mm and a compression ratio of 2.0 was used along with a gear pump with a capacity of 3 cc / rev. The height of the spin line was set at 2500 mm. The spinneret had 48 orifices, 400 microns diameter, and 640 microns depth (L / R of 1.6). The melt processing parameters were adjusted to get a stable process and afterwards a yam as fine as possible with the feasible draw ratio. The processing parameters are mentioned in Table 1.Table 1284900-0239-706695610.11916[000121] The linear density of spun yams was determined by utilizing a Zweigle L232. 50 meters of yam was collected with a pretension of 5 mN / tex (n=3). The mass of the yam was measured on an analytical balance. Tensile properties were determined according to ASTM D855 / D2256 by utilizing an Instron tensile tester model 5564. The tensile tester was equipped with a 1 kN load cell and pneumatic yarn grips. A crosshead speed of 250 mm / min and gauge length of 250 mm was used. Each specimen was measured 5 times (n=5) with a pretension of 5 mN / tex and a yam twist of 60 TPM. The mechanical properties of the spun yarns are described below in Table 2.Table 2Moisture Absorption properties[000122] The key to enhanced moisture performance lies in the careful selection of the polyhydroxyalkanoate polymer, (Polymer B, such as carbon-negative Aircarbon® polymer), and the Compatibilizer Package C. The carbon-negative polymer introduces hydrophilic properties to the inherently hydrophobic polypropylene, while the Compatibilizer Package C ensures proper interfacial adhesion between the two polymers, resulting in a stable and uniform fiber structure.Moisture Content Test294900-0239-706695610.11916[000123] The moisture content of the hydroxyalkanoate-polypropylene fiber alloy and virgin polypropylene fibers was analyzed according to ASTM D2654. This standard test method involves drying the fiber samples in an oven at a specified temperature until a constant weight is achieved.[000124] Following the procedure, pre-weighed samples (around 10g) of both the novel carbon-captured polypropylene fiber alloys and the virgin polypropylene fibers were placed in an oven maintained at 105 ± 3 °C. The samples were dried until no further weight loss was observed, indicating the complete removal of moisture. The moisture content was then calculated as the percentage of the weight loss relative to the initial weight of the fiber sample. The test was repeated three times to minimize error. The hydroxyalkanoate-polypropylene fiber alloys showed double of moisture content due to its enhanced hydrophilicity in compared to the virgin polypropylene fibers. See Figure 2.Vertical Wicking Test[000125] To evaluate the wicking performance of the hydroxyalkanoate-polypropylene fiber alloy, a vertical wicking test was conducted according to AATCC TM197-201 le2 (2018). This test method measures the rate at which water is transported vertically along a fabric sample. Knitted fabrics were produced from both the novel hydroxyalkanoate-polypropylene fiber alloy yams and virgin polypropylene yams to assess their wicking capabilities.[000126] Following the standardized procedure, the fabric samples were suspended vertically with their lower edges immersed in a controlled water reservoir. A few drops of water-soluble red dye were added for better visual measurement, See Figure 3. The height of the water wicking up the fabric was measured at regular time intervals. The wicking rate was then determined by analyzing the relationship between the wicking height and time, as shown in Figure 4.[000127] The results of the vertical wicking test clearly demonstrated the superior wicking performance of the hydroxyalkanoate-polypropylene fiber alloy. The hydroxyalkanoate-polypropylene fiber alloy fabric exhibited a wicking rate approximately double that of the virgin polypropylene fabric. This enhanced wicking capability can be attributed to the increased hydrophilicity of the hydroxyalkanoate-polypropylene alloy fibers, which facilitates faster water absorption and transport through the fabric structure. This surprising finding highlights the potential of this novel hydroxyalkanoate-polypropylene alloy for applications where efficient moisture management is crucial, such as sportswear and other performance textiles.304900-0239-706695610.11916Additional Embodiments[000128] In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than restrictive sense.[000129] Indeed, although this invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses of the invention and obvious modifications and equivalents thereof. In addition, while several variations of the embodiments of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the embodiments of the disclosed invention. Any methods disclosed herein need not be performed in the order recited. Thus, it is intended that the scope of the invention herein disclosed should not be limited by the particular embodiments described above.[000130] It will be appreciated that the systems and methods of the disclosure each have several innovative aspects, no single one of which is solely responsible or required for the desirable attributes disclosed herein. The various features and processes described above may be used independently of one another or may be combined in various ways. All possible combinations and subcombinations are intended to fall within the scope of this disclosure.[000131] Certain features that are described in this specification in the context of separate embodiments also may be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment also may be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination may in some cases be excised from the combination, and the claimed 314900-0239-706695610.11916combination may be directed to a subcombination or variation of a subcombination. No single feature or group of features is necessary or indispensable to each and every embodiment.[000132] It will also be appreciated that conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and / or steps. Thus, such conditional language is not generally intended to imply that features, elements and / or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and / or steps are included or are to be performed in any particular embodiment. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. In addition, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. In addition, the articles “a,” “an,” and “the” as used in this application and the appended claims are to be construed to mean “one or more” or “at least one” unless specified otherwise. Similarly, while operations may be depicted in the drawings in a particular order, it is to be recognized that such operations need not be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Further, the drawings may schematically depict one more example process in the form of a flowchart. However, other operations that are not depicted may be incorporated in the example methods and processes that are schematically illustrated. For example, one or more additional operations may be performed before, after, simultaneously, or between any of the illustrated operations. Additionally, the operations may be rearranged or reordered in other embodiments. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems may generally be integrated together in a single software product or packaged into multiple software products. Additionally, other embodiments are within the scope of the following claims.324900-0239-706695610.11916In some cases, the actions recited in the claims may be performed in a different order and still achieve desirable results.[000133] Further, while the methods and devices described herein may be susceptible to various modifications and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but, to the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the various implementations described and the appended claims. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with an implementation or embodiment can be used in all other implementations or embodiments set forth herein. Any methods disclosed herein need not be performed in the order recited. The methods disclosed herein may include certain actions taken by a practitioner; however, the methods can also include any third-party instruction of those actions, either expressly or by implication. The ranges disclosed herein also encompass any and all overlap, subranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited. Numbers preceded by a term such as “about” or “approximately” include the recited numbers and should be interpreted based on the circumstances (e.g., as accurate as reasonably possible under the circumstances, for example ±5%, ±10%, ±15%, etc.). For example, “about 3.5 mm” includes “3.5 mm.” Phrases preceded by a term such as “substantially” include the recited phrase and should be interpreted based on the circumstances (e.g., as much as reasonably possible under the circumstances). For example, “substantially constant” includes “constant.” Unless stated otherwise, all measurements are at standard conditions including temperature and pressure.[000134] As used herein, a phrase referring to “at least one of’ a list of items refers to any combination of those items, including single members. As an example, “at least one of A, B, or C” is intended to cover: A, B, C, A and B, A and C, B and C, and A, B, and C. Conjunctive language such as the phrase “at least one of X, Y and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be at least one of X, Y or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present. The headings provided334900-0239-706695610.11916herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.[000135] Accordingly, the claims are not intended to be limited to the embodiments shown herein but are to be accorded the widest scope consistent with this disclosure, the principles and the novel features disclosed herein. Overall, the language of the claims is to be interpreted broadly based on the language employed in the claims. The claims are not to be limited to the non-exclusive embodiments and examples that are illustrated and described in this disclosure, or that are discussed during the prosecution of the application.[000136] Those skilled in the art will also appreciate that in some embodiments the functionality provided by the components, structures, methods and processes discussed above may be provided in alternative ways, such as being split among more components or methods or consolidated into fewer components or methods. In addition, while various methods may be illustrated as being performed in a particular order, those skilled in the art will appreciate that in other embodiments the methods may be performed in other orders and in other manners.[000137] Also, although there may be some embodiments within the scope of this disclosure that are not expressly recited above or elsewhere herein, this disclosure contemplates and includes all embodiments within the scope of what this disclosure shows and describes. Further, this disclosure contemplates and includes embodiments comprising any combination of any structure, material, step, or other feature disclosed anywhere herein with any other structure, material, step, or other feature disclosed anywhere herein.[000138] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.[000139] Moreover, while components and operations may be depicted in the drawings or described in the specification in a particular arrangement or order, such components and operations need not be arranged and performed in the particular arrangement and order shown, nor in sequential order, nor include all of the components 344900-0239-706695610.11916and operations, to achieve desirable results. Other components and operations that are not depicted or described can be incorporated in the embodiments and examples. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.[000140] In summary, various illustrative embodiments and examples of a renewable and sustainable process for the production of pyrolysis products have been disclosed. Although the systems, techniques, and methods have been disclosed in the context of those embodiments and examples, this disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and / or other uses of the embodiments, as well as to certain modifications and equivalents thereof. This disclosure expressly contemplates that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another. Accordingly, the scope of this disclosure should not be limited by the particular disclosed embodiments described above but should be determined only by a fair reading of the claims that follow as well as their full scope of equivalents.354900-0239-7066

Claims

95610.11916WHAT IS CLAIMED IS:

1. A material alloy for a woven or non-woven fiber comprising:a first thermoplastic polymer comprising a polyhydroxyalkanoate, wherein the polyhydroxyalkanoate is between about 0.1 and about 30 parts by mass of the total mass of the alloy; anda second thermoplastic polymer,wherein the second thermoplastic polymer is not a polyhydroxy alkanoate,wherein the second thermoplastic polymer is between about 70 and about 99.9 parts by mass of a total mass of the alloy;a compatibilizer package,wherein the compatibilizer comprises a third polymer, wherein the compatibilizer is between about 0.1 to about 15 parts by mass of the total mass of the alloy, andwherein the total mass of the alloy is 100 parts by mass.

2. The material alloy of Claim 1, wherein the compatibilizer comprises a polyolefin elastomer and an acrylic acid-propylene copolymer.

3. The material alloy of Claim 1, wherein the polyhydroxyalkanoate comprises a polyhydroxybutyrate.

4. The material alloy of Claim 3, wherein the polyhydroxybutyrate is a carbonnegative polyhydroxybutyrate.

5. The material alloy of Claim 1, wherein the polyhydroxyalkanoate comprises one or more of PHB, PHBV, P(3HB-co-3HHx), P(3HB-co-4HB), or blends thereof.

6. The material alloy of Claim 1, wherein the polyhydroxyalkanoate comprises virgin PHA, recycled PHA, or modified PHA (e.g., end-capped, grafted, or chain-extended).364900-0239-706695610.119167. The material alloy of Claim 1, wherein the second thermoplastic polymer comprises polypropylene, polyethylene terephthalate, polylactic acid, or combinations thereof.

8. The material alloy of Claim 7, wherein the second thermoplastic polymer comprises polypropylene.

9. The material alloy of Claim 8, wherein the polypropylene comprises a polypropylene homopolymer.

10. The material alloy of Claim 9, wherein the polypropylene homopolymer is between about 80 parts and about 90 parts by mass, with respect to a total of 100 parts by mass of said alloy.

11. The material alloy of Claim 1, wherein said polyhydroxyalkanoate is between about 10 parts and about 2 parts by mass, and said compatibilizer package is between about 2 and about 8 parts by mass with respect to a total of 100 parts by mass of said alloy.

12. The material alloy of Claim 1, wherein the second thermoplastic polymer is between about 85 parts and about 99 parts by mass, said polyhydroxyalkanoate is between about 7 parts and about 4 parts by mass, and said compatibilizer package is between about 2 and about 4 parts by mass with respect to a total of 100 parts by mass of said alloy.

13. The material alloy of Claim 1, wherein the compatibilizer package comprises a polyolefin elastomer that has both metallocene and non-metallocene with elastomeric properties.

14. The material alloy of Claim 1, further comprising a non-thermoplastic polymer.

15. The material alloy of Claim 14, wherein the non-thermoplastic polymer comprises a semi -synthetic cellulose fiber, a synthetic cellulose fiber, or a natural cellulose fiber.

16. The material alloy of Claim 15, wherein the non-thermoplastic polymer comprises Tencel™.374900-0239-706695610.1191617. The material alloy of any one of Claims 1 to 16, wherein said material alloy has a vertical wicking rate that is double that of virgin polypropylene.

18. The material alloy of any one of Claims 1 to 16, wherein said material alloy has a moisture absorption rate that is double that of virgin polypropylene.

19. The material alloy of any one of Claims 1 to 18, wherein the alloy is suitable for processing by a meltblown, spunblown, spunbond, injection molding, compression molding, blow molding, rotational molding, extrusion, thermoforming, calendaring, casting, fiber spinning, compounding, or 3D printing process.

20. The material alloy of any one of Claims 1 to 19, wherein the alloy is suitable for processing to generate a non-woven fiber, a multifilament fiber, a monofilament fiber, a stable fiber, a tape yarn, or a geotextile.

21. The material alloy of any one of Claims 1 to 20, further comprising one or more additional fiber components.

22. The material alloy of Claim 21, wherein the one or more additional fiber components is selected from the group consisting of natural fibers, regenerated cellulosic fibers, bio-based synthetic fibers, inorganic, carbon and / or metal fiber, aramid fibers, polybenzoxazole fibers, conductive or anti-static fibers, flame-retardant fibers, antimicrobial fibers, superabsorbent fibers and / or bicomponent binder fibers, or combinations thereof.

23. The material alloy of Claim 21, wherein the additional fiber components enhance one or more of the feel, texture, breathability, durability, colorability, stain resistance, odor resistance, sun protection factor or other characteristic of an article manufactured in whole or in part with the alloy comprising the additional fiber(s).

24. A hydroxyalkanoate-polypropylene fiber alloy comprising:(a) a polypropylene;(b) a polyhydroxyalkanoate; and(c) a compatibilizer package, wherein said compatibilizer package comprises a polyolefin elastomer and an acrylic acid-propylene copolymer.384900-0239-706695610.1191625. The hydroxyalkanoate-polypropylene fiber alloy of claim 24, wherein said polypropylene is a polypropylene is 65 parts to 99.75 parts by mass, said carbon-negative polyhydroxybutyrate is 25 parts to 1 part by mass, and said compatibilizer package is 1 to 10 parts by mass with respect to a total of 100 parts by mass of said polypropylene homopolymer, said carbon-negative polyhydroxybutyrate, and said compatibilizer package.

26. The hydroxyalkanoate-polypropylene fiber alloy of claim 25, wherein said polypropylene homopolymer is 80 parts to 90 parts by mass, said carbon-negative polyhydroxybutyrate is 10 parts to 2 parts by mass, and said compatibilizer package is 2 to 8 parts by mass with respect to a total of 100 parts by mass of said polypropylene homopolymer, said carbon-negative polyhydroxybutyrate, and said compatibilizer package.

27. The hydroxyalkanoate-polypropylene fiber alloy of claim 26, wherein said polypropylene homopolymer is 85 parts to 90 parts by mass, said carbon-negative polyhydroxybutyrate is 7 parts to 4 parts by mass, and said compatibilizer package is 2 to 4 parts by mass with respect to a total of 100 parts by mass of said polypropylene homopolymer, said carbon-negative polyhydroxybutyrate, and said compatibilizer package.

28. The hydroxyalkanoate-polypropylene fiber alloy of claim 24, wherein said polypropylene is a polypropylene homopolymer.

29. The hydroxyalkanoate-polypropylene fiber alloy of claim 24, wherein said polyolefin elastomer has both metallocene and non-metallocene with elastomeric properties.

30. The hydroxyalkanoate-polypropylene fiber alloy of claim 24, wherein said hydroxyalkanoate-polypropylene fiber alloy has a vertical wicking rate that is double that of virgin polypropylene.394900-0239-706695610.1191631. The hydroxyalkanoate-polypropylene fiber alloy of claim 24, wherein said hydroxyalkanoate-polypropylene fiber alloy has a moisture absorption rate that is double that of virgin polypropylene.

32. The metal alloy of claim 1, wherein said polyhydroxyalkanoate comprises one of polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), polyhydroxybutyratecovalerate (PHBV), polyhydroxyhexanoate (PHHx) and blends thereof, and short chain length (SCL), medium chain length (MCL), and long chain length (LCL) PHAs.

33. The metal alloy of claim 1, wherein said PHA is selected from polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), polyhydroxybutyrate-covalerate (PHBV), polyhydroxyhexanoate (PHHx), poly 3 -hydroxy alkanoates (e.g., poly 3-hydroxypropionate (hereinafter referred to as P3HP), poly 3 -hydroxybutyrate (hereinafter referred to as PHB) and poly 3 -hydroxy valerate), poly 4-hydroxyalkanoates (e.g., poly 4-hydroxybutyrate (hereinafter referred to as P4HB), or poly 4-hydroxyvalerate (hereinafter referred to as P4HV)) and poly 5 -hydroxy alkanoates (e.g., poly 5 -hydroxy valerate (hereinafter referred to as P5HV)), poly 3 -hydroxybutyrate-co-3 -hydroxypropionate (hereinafter referred to as PHB3HP), poly 3-hydroxybutyrate-co-4-hydroxybutyrate (hereinafter referred to as PHB4HB), poly 3 -hydroxybutyrate-co-4-hydroxy valerate (hereinafter referred to as PHB4HV), poly 3 -hydroxybutyrate-co-3 -hydroxy valerate (hereinafter referred to as PHB3HV), poly 3 -hydroxybutyrate-co-3 -hydroxyhexanoate (hereinafter referred to as PHB3HH) and poly 3-hydroxybutyrate-co-5-hydroxyvalerate (hereinafter referred to as PHB5HV) and various combinations thereof, including polymer blends.

34. A hydroxyalkanoate-polypropylene fiber alloy comprising:(a) a polypropylene,wherein the polypropylene is between about 60 and about 99.75 parts by mass of a total mass of the alloy;(b) a polyhydroxybutyrate,wherein the polyhydroxybutyrate is between about 1 and about 30 parts by mass of the total mass of the alloy; and(c) a compatibilizer package,wherein the compatibilizer comprises a polyolefin elastomer and an acrylic acid-propylene copolymer,404900-0239-706695610.11916wherein the compatibilizer is between about 1 to about 15 parts by mass of the total mass of the alloy, andwherein the total mass of the alloy is 100 parts by mass.

35. The hydroxyalkanoate-polypropylene fiber alloy of claim 34, wherein the polyhydroxybutyrate is a carbon-negative polyhydroxybutyrate.

36. The hydroxyalkanoate-polypropylene fiber alloy of claim 34 or 35, wherein said polypropylene homopolymer is between about 80 parts and about 90 parts by mass, said polyhydroxybutyrate is between about 10 parts and about 2 parts by mass, and said compatibilizer package is between about 2 and about 8 parts by mass with respect to a total of 100 parts by mass of said alloy.

37. The hydroxyalkanoate-polypropylene fiber alloy of any one of Claims 34 to 36, wherein said polypropylene homopolymer is between about 85 parts and about 90 parts by mass, said polyhydroxybutyrate is between about 7 parts and about 4 parts by mass, and said compatibilizer package is between about 2 and about 4 parts by mass with respect to a total of 100 parts by mass of said alloy.

38. The hydroxyalkanoate-polypropylene fiber alloy of any one of Claims 34 to 37, wherein said polypropylene is a polypropylene homopolymer.

39. The hydroxyalkanoate-polypropylene fiber alloy any one of Claims 34 to 38, wherein said polyolefin elastomer has both metallocene and non-metallocene with elastomeric properties.

40. The hydroxyalkanoate-polypropylene fiber alloy of any one of Claims 34 to 39, wherein said hydroxyalkanoate-polypropylene fiber alloy has a vertical wicking rate that is double that of virgin polypropylene.

41. The hydroxyalkanoate-polypropylene fiber alloy of any one of Claims 34 to 40, wherein said hydroxyalkanoate-polypropylene fiber alloy has a moisture absorption rate that is double that of virgin polypropylene.414900-0239-706695610.1191642. The hydroxyalkanoate-polypropylene fiber alloy of any one of Claims 34 to 41, wherein the alloy is suitable for processing by a meltblown, spunblown, spunbond, injection molding, compression molding, blow molding, rotational molding, extrusion, thermoforming, calendaring, casting, fiber spinning, compounding, or 3D printing process.

43. The hydroxyalkanoate-polypropylene fiber alloy of any one of Claims 34 to 42, wherein the alloy is suitable for processing to generate a non-woven fiber, a multifilament fiber, a monofilament fiber, a stable fiber, a tape yam, or a geotextile.

44. The hydroxyalkanoate-polypropylene fiber alloy of any one of Claims 34 to 43, further comprising one or more additional fiber components.

45. The hydroxyalkanoate-polypropylene fiber alloy of Claim 44, wherein the one or more additional fiber components is selected from the group consisting of natural fibers, regenerated cellulosic fibers, bio-based synthetic fibers, inorganic, carbon and / or metal fiber, aramid fibers, polybenzoxazole fibers, conductive or anti-static fibers, flameretardant fibers, antimicrobial fibers, superabsorbent fibers and / or bicomponent binder fibers, or combinations thereof.

46. The hydroxyalkanoate-polypropylene fiber alloy of Claim 44, wherein the additional fiber components enhance one or more of the feel, texture, breathability, durability, colorability, stain resistance, odor resistance, sun protection factor or other characteristic of an article manufactured in whole or in part with the alloy comprising the additional fiber(s).

47. A material alloy for a woven or non-woven fiber comprising:a polyhydroxyalkanoate,wherein the polyhydroxyalkanoate is between about 0.1 and about 30 parts by mass of the total mass of the alloy; anda non- polyhydroxyalkanoate thermoplastic polymer,wherein the non- polyhydroxyalkanoate thermoplastic polymer is between about 70 and about 99.9 parts by mass of a total mass of the alloy; a compatibilizer package,wherein the compatibilizer comprises an elastomer and a copolymer,424900-0239-706695610.11916wherein the compatibilizer is between about 0.1 to about 15 parts by mass of the total mass of the alloy, andwherein the total mass of the alloy is 100 parts by mass.

48. The fiber alloy of Claim 47, wherein the compatibilizer comprises a polyolefin elastomer and an acrylic acid-propylene copolymer.434900-0239-7066

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