FAR INFRARED RADIATION NANOFIBER YARN COMPOSITION

Description

TECHNICAL FIELD

The present disclosure generally relates to far infrared radiation (FIR) yarn that may be used to create various textiles having multiple benefits for the human body. In particular, the present disclosure relates to FIR yarn created from fiber made using a masterbatch and an extrusion process.

BACKGROUND

Traditionally textiles, garments, clothes, leisure-wear and athletic-wear such as shirts, pants, shorts, socks, underwear, hats, shoes, wristbands, headbands, sweatbands, rash guards, athletic sleeves, compression sleeves, braces, body/joint wraps, protective equipment, blankets, sheets, linens, comforters, pillowcases, towels, etc. are made from cotton, polyester, nylon, spandex, silk, wool, Lycra, leather and the like. Garments made from such materials traditionally do not provide added benefits to the wearer such as increased artery blood flow, increased peripheral blood circulation, improved endothelial function, increased growth of collagen and elastin in the skin, reduced dry and itchy skin, improved temperature regulation and improved moisture regulation.

Far infrared radiation (FIR) produces both thermal and o-thermal effects to the human body, and has been shown to increase artery blood flow, increase peripheral blood circulation, improve endothelial function, alleviate fatigue and pain, reduce blood pressure and promote capillary dilations. Additionally, FIR is beneficial in treating diseases such as, but not limited to, cardiovascular disease, diabetes mellitus, chronic kidney disease and ischemia, and is effective in relieving pain in patients with chronic pain, chronic fatigue syndrome, and fibromyalgia. FIR may be used for physical ailments such as muscle damage in a person, and has mental health benefits for patients suffering from depression and insomnia by increasing serotonin and reducing malondialdehyde levels. Typically, the global industry standard for claiming improved FIR performance is the Chinese test standard GB/T 30127-2013. In accordance with the GB/T 30127-2013 standard, to claim improved FIR performance, the minimum requirement FIR emissivity from the material is 0.88, and the minimum requirement for temperature rise in the material (i.e., FIR temperature rise) is 1.4° C.

FIR helps to increase blood flow and vasodilation by heating human tissue in the body; these benefits are similar to applying heat pads or hot water to the body. FIR treatment even at low levels has been shown to have many additional positive therapeutic and biological benefits, such as reducing pain and inflammation, improving blood circulation, detoxifying the body, promoting relaxation and reducing stress, increasing collagen synthesis, strengthening the cardiovascular system, boosting the immune system, and reducing depression.

Obsidian is known to possess beneficial properties for humans. For example, obsidian is known to reduce pain and inflammation in muscles and joints as well as to assist in detoxifying the body. Obsidian is also a natural antimicrobial and has anti-odor or odor reducing properties, which can be especially beneficial when used in athletic garments. Obsidian is an effective thermal conductor. It helps preserve heat in cold weather and reduce or eliminate heat in warm weather. Obsidian fibers are also very strong having ultra-high tensile strength. These above characteristics are ideal for athletic sleeves, compression sleeves and garments.

SUMMARY

The present disclosure generally relates to FIR yarn that may be used to create various textiles having multiple benefits for the human body. In particular, the present disclosure relates to FIR yarn created from fiber made using a masterbatch and an extrusion process.

The present disclosure relates to FIR yarn that may be used to create various textiles, garments, clothes, leisure-wear and athletic-wear such as shirts, pants, shorts, socks, underwear, hats, shoes, wristbands, headbands, sweatbands, rash guards, athletic sleeves, compression sleeves, braces, body/joint wraps, protective equipment, blankets, sheets, linens, comforters, pillowcases, towels, etc. having multiple benefits for the human body. The FIR yarn may comprise one or more of obsidian, copper, graphene, germanium, titanium, silica, magnesium, strontium, silicon dioxide, titanium dioxide, magnesite, calcite, rhodochrosite, siderite, smithsonite, aragonite, strontianite, smithsonite, witherite, cerrusite, huntite, dolomite, ankerite, kutnohorite, hydroincite, hydroomagnesite, artinite, galussite, trona, ankerite, aragonite, artinite, and combinations thereof.

It is further contemplated that the textiles, garments, clothes, leisure-wear and athletic-wear created from the FIR yarn will have one or more benefits to the wearer, such as increased artery blood flow, increased peripheral blood circulation, improved endothelial function, improved capillary dilations, reduced fatigue and pain, reduced blood pressure, increased growth of collagen and elastin in the skin, reduced dry and itchy skin, reduced odor, improved temperature regulation, and improved moisture regulation.

In one embodiment, a FIR yarn composition is disclosed, comprising: one or more FIR fibers comprising obsidian and a first textile material; and one or more textile fibers comprising a second textile material; wherein the one or more FIR fibers are interwoven with the one or more textile fibers to form the FIR yarn composition.

In one embodiment, the one or more FIR fibers comprise nanofibers with a diameter of less than 100 nanometers.

In one embodiment, an FIR emissivity of the FIR yarn composition is at least 0.83.

In one embodiment, the FIR emissivity is at least 0.88.

In one embodiment, an FIR temperature rise of the FIR yarn composition is at least 1.4° C.

In one embodiment, the FIR temperature rise is at least 1.7° C.

In one embodiment, the one or more FIR fibers are formed by producing masterbatch pellets using obsidian powder and a base polymer, melting the masterbatch pellets and the first textile material to form an extrusion material, and extruding the extrusion material to form the one or more FIR fibers.

In one embodiment, the masterbatch pellets comprise 30% by weight of obsidian powder.

In one embodiment, the FIR fibers comprise 5% by weight of the masterbatch pellets.

In one embodiment, the first textile material comprises polyethylene terephthalate (PET).

In one embodiment, the first textile material comprises Nylon 6 (N6).

In one embodiment, the second textile material comprises polyethylene terephthalate (PET).

In one embodiment, the second textile material comprises Nylon 6 (N6).

In one embodiment, the FIR yarn composition is configured to be incorporated into a textile product selected from the group consisting of shirts, pants, shorts, socks, underwear, hats, shoes, wristbands, headbands, sweatbands, rash guards, athletic sleeves, compression sleeves, braces, body/joint wraps, protective equipment, blankets, sheets, linens, comforters, pillowcases, towels.

In one embodiment, the obsidian powder comprises approximately 42-49% by weight of oxygen, approximately 4-8% by weight of aluminum, approximately 15-25% by weight of silicon, approximately 1-4% by weight of potassium, approximately 6-28% by weight of carbon, approximately 1-2% by weight of magnesium, approximately 3-6% by weight of iron, approximately 0-2% by weight of sodium, and approximately 2-5% by weight of tungsten.

In one embodiment, the obsidian powder comprises approximately 42.1% by weight of oxygen, approximately 4.8% by weight of aluminum, approximately 15.8% by weight of silicon, approximately 1.6% by weight of potassium, approximately 27.7% by weight of carbon, approximately 1.0% by weight of magnesium, approximately 3.1% by weight of iron, approximately 0.9% by weight of sodium, and approximately 2.5% by weight of tungsten.

In one embodiment, the obsidian powder comprises approximately 0.5% by weight of copper.

In one embodiment, the obsidian powder comprises approximately 48.2% by weight of oxygen, approximately 7.9% by weight of aluminum, approximately 24.9% by weight of silicon, approximately 2.9% by weight of potassium, approximately 6.5% by weight of carbon, approximately 1.1% by weight of magnesium, approximately 4.2% by weight of iron, approximately 0.9% by weight of sodium, and approximately 4.6% by weight of tungsten.

In one embodiment, the masterbatch pellets comprise approximately 65-67% by weight of carbon, approximately 23-26% by weight of oxygen, approximately 4-6% by weight of silicon, approximately 1-2% by weight of aluminum, approximately 0-1% by weight of iron, approximately 0-1% by weight of potassium, approximately 0-1% by weight of calcium, approximately 0-1% by weight of magnesium, and approximately 0-1% by weight of sodium.

In one embodiment, the masterbatch pellets comprise approximately 65.7% by weight of carbon, approximately 26.0% by weight of oxygen, approximately 4.6% by weight of silicon, approximately 1.5% by weight of aluminum, approximately 1.0% by weight of iron, approximately 0.5% by weight of potassium, approximately 0.3% by weight of calcium, approximately 0.3% by weight of magnesium, and approximately 0.1% by weight of sodium.

BRIEF DESCRIPTION OF DRAWINGS

A further understanding of the present disclosure can be obtained by reference to a preferred embodiment set forth in the illustrations of the accompanying drawings. Although the illustrated embodiment is merely exemplary of systems and methods for carrying out the invention, both the organization and method of operation of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention.

For a more complete understanding of the present disclosure, reference is now made to the following drawings in which:

FIG. 1 depicts an illustrative method for manufacturing FIR yarn according to an embodiment of the present disclosure; and

FIG. 2 depicts an illustrative spool of FIR yarn according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

The detailed description set forth below is intended as a description of various FIR yarn compositions and methods for making the same and is not intended to represent the only way the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the various concepts. It will be apparent, however, to those skilled in the art that these concepts may be practiced without all of these specific details. In some instances, well-known elements are only briefly mentioned or described in order to avoid obscuring the material aspects of the present disclosure.

Reference may be made herein to other United States patents, foreign patents, and/or other technical references. Any reference made herein to other documents is an express incorporation by reference of the document so referenced in its entirety.

The present disclosure generally relates to FIR yarns to be used in various products configured for contact with the human body to provide the benefits of FIR described above. The FIR yarns may be used in products such as, but not limited to, clothing, shirts, pants, shorts, socks, underwear, hats, shoes, wristbands, headbands, sweatbands, rash guards, athletic sleeves, compression sleeves, braces, body/joint wraps, protective equipment, blankets, sheets, linens, comforters, pillowcases, towels, and any other desirable textiles.

FIG. 1 depicts an illustrative method for manufacturing an FIR yarn according to an embodiment of the present disclosure.

At step 102, a concentration of obsidian for high-concentration masterbatch pellets may be determined. The concentration of obsidian may be determined based on the requirements of the final textile product. In one embodiment, an amount of obsidian used for the masterbatch pellets may be a fixed amount. For example, the amount of obsidian may be fixed at 30 percent by weight (wt. %). The amount of obsidian may be chosen to produce masterbatch pellets for a yarn having adequate FIR emissivity, tensile strength, elasticity, etc. in a produced textile fabric. In other words, the amount of obsidian may be chosen based on the FIR emissivity requirements, tensile strength requirements, elasticity, etc. of a final yarn to be produced.

At step 104, high-concentration masterbatch pellets may be produced by mixing an amount of obsidian powder with an amount of a base polymer, which may be virgin polyethylene terephthalate (PET) chips, nylon 6 (N6) chips, or the like to create masterbatch pellets. The base polymer (e.g., virgin PET, N6 chips, etc.) may be thoroughly mixed with the obsidian powder to ensure uniform dispersion. Once mixed, the masterbatch pellets may be produced, achieving a high concentration of obsidian. In one embodiment, the masterbatch pellets may comprise of 30 wt. % of obsidian powder and 70 wt. % of PET chips.

At step 106, the high-concentration masterbatch pellets may be mixed with virgin standard PET, N6 chips, or the like, melted, and extruded to form fibers. The proportion of masterbatch pellets to virgin polymer chips added during this step may vary and may be determined by the desired concentration of obsidian in the final fiber. In one embodiment, obsidian polyester fibers may be formed by adding 5 wt. % of the masterbatch pellets to 95 wt. % PET chips. In one embodiment, the final fiber may be a nanofiber with a diameter less than 100 nanometers (nm).

At step 108, the extruded fiber containing obsidian may be woven or twisted together with PET, N6, or similar fibers to form a yarn. The weaving process may involve combining the functionalized fibers (e.g., the FIR fibers) with non-functionalized fibers (e.g., traditional textile fibers) in various proportions, depending on the desired characteristics of the final yarn. This step may allow for the integration of the FIR properties of the obsidian fiber with the mechanical strength and flexibility of the standard PET, N6 or similar fibers, resulting in a hybrid yarn tailored for specific end-use applications such as textiles, technical fabrics, or industrial products. For example, without limitation, fabric for a T-shirt may be composed of 68% obsidian polyester fibers and 32% traditional textile fibers to produce a fabric having elevated FIR emissivity. In another example, fabric for a T-shirt may be composed of 23% obsidian polyester fibers, resulting in a fabric having lower FIR emissivity but which may be produced at a lower cost.

The ability to adjust obsidian concentration in the masterbatch pellets, vary the masterbatch pellet content during fiber extrusion, and vary the FIR fibers during fiber weaving enables customization for specific end-use applications. The mixing process may ensure uniform dispersion of obsidian within the masterbatch pellets, translating to consistent properties in the final yarn product. The use of high-concentration masterbatch pellets may also simplify the production process by allowing the fiber producer to easily adjust the concentrations of obsidian to meet precise specifications without needing to handle multiple materials during the fiber extrusion process.

FIG. 2 depicts an illustrative spool of FIR yarn according to an embodiment of the present disclosure. Spool 202 of FIG. 2 may be produced by the process detailed in FIG. 1, and may have differing attributes based on, for example, an amount of obsidian used to produce the masterbatch pellets, the type of textile material mixed into the masterbatch pellets, the amount of textile material used to produce the masterbatch pellets, the type and amount of textile material mixed with the masterbatch pellets before extrusion, and the amount and type of textile fiber interwoven with the extruded FIR fiber. As obsidian powder may be used in the production of spool 202, a white or light colored yarn may be produced. The white or light colored yarn may be more easily dyed a desired color than, for example, a dark colored yarn, while still retaining the FIR and other properties detailed above.

In one embodiment of the present disclosure, multiple ingredients (e.g., elements and/or minerals) are utilized to produce FIR in a single yarn to achieve levels of FIR emission meeting global industry standards, such as the GB/T 30127-2013 standard.

The present disclosure may incorporate ingredients such as obsidian, copper, germanium, titanium, silica, graphene, magnesium, strontium, silicon dioxide, titanium dioxide, magnesite, calcite, rhodochrosite, siderite, smithsonite, aragonite, strontianite, smithsonite, witherite, cerrusite, huntite, dolomite, ankerite, kutnohorite, hydroincite, hydroomagnesite, artinite, galussite, trona, ankerite, aragonite, artinite, and combinations thereof to produce an FIR yarn with ample FIR emissivity.

In one embodiment, in order to incorporate these ingredients into a yarn, the desired elements, such as obsidian, are first processed (e.g., crushed or pulverized) into particles and mixed with a base polymer to create pellets. The pellets are then combined with traditional textile material such as a polyester, nylon, or the like. There are various types of polyester and nylon that can be used such as polypropylene (PP), polyethylene (PE), polycarbonate (PC), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), polyamide 6 (PA6), nylon 6 (N6), or any other nylon and polyester forms. Once the pellets and the traditional textile material are combined, they may be mixed and heated in a vat until melted. Once sufficiently mixed, heated and melted, the contents may then extruded to create fibers. The extruded fibers are then used to create a yarn that has FIR properties. It should be noted that the pellets created from the ingredients having FIR properties can also be incorporated into durable goods, not just textile related products.

The ingredients chosen and the amount of each chosen ingredient influence the emissivity level of the yarns and are measured in weight percentage (wt. %) relative to the fibers and/or yarn. Depending on the chosen ingredients, testing is performed to determine how much of each ingredient must be added to create a yarn that is commercially useable. If too much of a certain ingredient is chosen, the resulting yarn may be prone to breaking during the manufacturing process and greatly effects the durability of the finished product.

FIR emissivity levels are not only determined by the ingredients that are used and the amount of each chosen ingredient, but also the diameter of the yarn itself. Generally, a larger diameter yarn has a greater level of FIR emissivity.

In addition the above-identified benefits, the FIR yarn produced from the ingredients identified and discussed herein also have the following additional benefits: improved durability, improved thermal insulation, etc.

As previously described, obsidian powder is mixed with a first standard textile material to produce masterbatch pellets, and masterbatch pellets are mixed with a second standard textile material, melted, and extruded to produce FIR fibers. With 30.0 wt. % of obsidian powder used to produce the masterbatch pellets, and 5.0 wt. % masterbatch pellets used to produce the FIR fibers, the resulting FIR fibers contain approximately 1.5 wt. % of obsidian.

Any type of obsidian known in the art may be used to produce the obsidian powder disclosed herein. In one embodiment, obsidian may comprise mainly silicone dioxide (SiO₂), with a remaining portion including other oxides, such as oxides of aluminum, iron, potassium, sodium and calcium.

In one embodiment of the invention, the obsidian powder is composed of one or more of oxygen, aluminum, silicon, potassium, carbon, magnesium, iron, sodium, tungsten, copper, titanium and/or calcium.

For the obsidian powder, in one embodiment, the oxygen content is in a range between 42 wt. %-49 wt. %, the aluminum content is in a range between 4 wt. %-8 wt. %, the silicon content is in a range between 15 wt. %-25 wt. %, the potassium content is in a range between 1 wt. %-4 wt. %, the carbon content is in a range between 6 wt. %-28 wt. %, the magnesium content is in a range between 1 wt. %-2 wt. %, the iron content is in a range between 3 wt. %-6 wt. %, the sodium content is in a range between 0 wt. %-2 wt. %, the tungsten content is in a range between 2 wt. %-5 wt. %, the copper content is in a range between 0 wt. %-1 wt. %, the titanium content is in a range between 0 wt. %-1 wt. %, and the calcium content is in a range between 0 wt. %-1 wt. %.

For the obsidian powder, in one embodiment, the oxygen content is 42.1 wt. %, the aluminum content is 4.8 wt. %, the silicon content is 15.8 wt. %, the potassium content is 1.6 wt. %, the carbon content is 27.7 wt. %, the magnesium content is 1.0 wt. %, the iron content is 3.1 wt. %, the sodium content is 0.9 wt. %, the tungsten content is 2.5 wt. %, and the copper content is 0.5 wt. %.

For the obsidian powder, in one embodiment, the oxygen content is 48.2 wt. %, the aluminum content is 7.9 wt. %, the silicon content is 24.9 wt. %, the potassium content is 2.9 wt. %, the carbon content is 6.5 wt. %, the magnesium content is 1.1 wt. %, the iron content is 4.2 wt. %, the sodium content is 0.9 wt. %, and the tungsten content is 3.4 wt. %.

For the obsidian powder, in one embodiment, the oxygen content is 44.1 wt. %, the aluminum content is 7.8 wt. %, the silicon content is 23.6 wt. %, the potassium content is 3.5 wt. %, the carbon content is 6.9 wt. %, the magnesium content is 1.2 wt. %, the iron content is 5.9 wt. %, the sodium content is 1.2 wt. %, the tungsten content is 4.6 wt. %, the titanium content is 0.5 wt. %, and the calcium content is 0.7 wt. %.

In one embodiment, the masterbatch pellets are composed of carbon, oxygen, silicon, aluminum, iron, potassium, calcium, magnesium, sodium, titanium, and/or copper.

For the masterbatch pellets, in one embodiment, the carbon content is in a range between 65 wt. %-67 wt. %, the oxygen content is in a range between 23 wt. %-26 wt. %, the silicon content is in a range between 4 wt. %-6 wt. %, the aluminum content is in a range between 1 wt. %-2 wt. %, the iron content is in a range between 1 wt. %-2 wt. %, the potassium content is in a range between 0 wt. %-1 wt. %, the calcium content is in a range between 0 wt. % -1 wt. %, the magnesium content is in a range between 0 wt. %-1 wt. %, the sodium content is in a range between 0 wt. %-1 wt. %, the titanium content is in a range between 0 wt. %-1 wt. %, and the copper content is in a range between 0 wt. %-1 wt. %.

For the masterbatch pellets, in one embodiment, the carbon content is 65.7 wt. %, the oxygen content is 26.0 wt. %, the silicon content is 4.6 wt. %, the aluminum content is 1.5 wt. %, the iron content is 1.0 wt. %, the potassium content is 0.5 wt. %, the calcium content is 0.3 wt. %, the magnesium content is 0.3 wt. %, and the sodium content is 0.1 wt. %.

For the masterbatch pellets, in one embodiment, the carbon content is 66.5 wt. %, the oxygen content is 24.7 wt. %, the silicon content is 4.8 wt. %, the aluminum content is 1.5 wt. %, the iron content is 1.1 wt. %, the potassium content is 0.5 wt. %, the calcium content is 0.4 wt. %, the magnesium content is 0.2 wt. %, the sodium content is 0.2 wt. %, and the titanium content is 0.1 wt. %.

For the masterbatch pellets, in one embodiment, the carbon content is 66.2 wt. %, the oxygen content is 23.6 wt. %, the silicon content is 5.4 wt. %, the aluminum content is 1.7 wt. %, the iron content is 1.4 wt. %, the potassium content is 0.6 wt. %, the calcium content is 0.3 wt. %, the magnesium content is 0.3 wt. %, the sodium content is 0.2 wt. %, and the copper content is 0.3 wt. %.

Adequate FIR emissivity and FIR temperature rise may depend on the type of textile produced. For example, without limitation, a T-shirt may have an adequate FIR emissivity greater than or equal to 0.88 and an adequate FIR temperature rise greater than or equal to 1.4° C. while socks may have an adequate FIR emissivity greater than or equal to 0.83 and an adequate FIR temperature rise greater than or equal to 1.7° C.

A shirt using the FIR yarn of the present embodiment may have an FIR emissivity equal to or greater than 0.92, preferably 0.94, and an FIR temperature rise greater than or equal to 1.9° C. Socks using the FIR yarn of the present embodiment may have an FIR emissivity greater than or equal to 0.88 and an FIR temperature rise greater than or equal to 2.4° C.

The textile may be additionally composed of fibers of other materials, such as, but not limited to, cotton, nylon, spandex, silk, wool, Lycra, and combinations thereof. The textile may be used to make garments such as shirts, pants, shorts, socks, underwear, hats, shoes, wristbands, headbands, sweatbands, rash guards, athletic sleeves, compression sleeves, braces, body/joint wraps, protective equipment, blankets, sheets, linens, comforters, pillowcases, towels, etc. The textile can be custom made to adjust or control the amount of obsidian in the garments. The percentage of obsidian may be adjusted in the fiber or yarn by controlling how much of each material is extruded into the yarn or fibers.

Once the yarn is created, the yarn may be used to create various textile products configured to be worn by a wearer or user such that the wearer or user is exposed to FIR, where the wearer or user receives the biological benefits from FIR exposure. These textile products may be for example, without limitation, garments such as shirts, pants, shorts, socks, underwear, hats, shoes, wristbands, headbands, sweatbands, rash guards, athletic sleeves, compression sleeves, braces, body/joint wraps, protective equipment, blankets, sheets, linens, comforters, pillowcases, towels, and the like.

The above detailed descriptions of embodiments of the present disclosure are not intended to be exhaustive or to limit the disclosure to the precise form disclosed herein. Although specific embodiments of, and examples for, the disclosure herein are described above for illustrative purposes, various equivalent modifications are possible within the scope of the disclosure, as those skilled in the relevant art will recognize. For example, while formulations comprise certain ingredients in certain amounts, alternative embodiments may incorporate additional ingredients not necessarily disclosed herein, be comprised of fewer ingredients, or have varying amounts of each ingredient without departing from the present disclosure. Further, while steps are presented in a given order, alternative embodiments may perform steps in a different order. The various embodiments described herein may also be combined to provide further embodiments applicable to a wide range of compositions.

Further, while advantages associated with certain embodiments of the technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall with the scope of this disclosure. Accordingly, this disclosure and associated inventions can encompass other embodiments not expressly shown or described herein.

Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the attendant claims attached hereto, this invention may be practiced otherwise than as specifically disclosed herein.