Metal/polymer composite fibers

Abstract

A specially engineered composite fiber is provided that is a combination of weight imparting particles and polymeric compounds, with a specific gravity totaling about 2 or greater. The composite fiber can be extruded and melt-spun like a normal polymeric fiber, thus creating a relatively heavy, weighted material fiber, sheet or fabric.

1 . A composite fiber containing a particle component and a polymer component, wherein discrete particles in the particle component impart to the composite fiber a specific gravity of at least 2.0. 
     
     
         2 . The composite fiber according to  claim 1 , wherein the composite fiber consists essentially of the particle component and the polymer component. 
     
     
         3 . The composite fiber according to  claim 2 , further comprising a material in a concentration not adversely affecting desirable properties of the composition fiber and chosen from the group consisting of antioxidant, stabilizer, surfactant, wax, flow promoter, solid solvent, and particulate. 
     
     
         4 . The composite fiber according to  claim 1 , wherein the particle component comprises elongated micro-threads imparting weight within the composite fiber. 
     
     
         5 . The composite fiber according to  claim 1 , wherein the particles comprise at least one material from the group consisting of iron, bronze, brass, steel, titanium, an alloy thereof, tin, copper, tungsten, platinum, silver, bismuth trioxide, ferrous oxide, silver oxide, organic compounds, pure polymeric compounds, and polymeric blends. 
     
     
         6 . The composite fiber according to  claim 1 , wherein the polymer component comprises at least one material from the group consisting of polyester, polyethylene terephthalate, polypropylene, NYLON, elastane, acetate, rayon, acrylics, Vinalon, polylactic acid blends, polyethylene (low or high density), polyvinyl chloride (PVC), and polystyrene, or combinations thereof. 
     
     
         7 . The composite fiber according to  claim 1 , wherein the fiber is configured as a single composition fiber having fiber units with a cross section that is one of circular, tri-lobal, multi-lobal and bow-tie shaped. 
     
     
         8 . The composite fiber according to  claim 1 , wherein the fiber is configured as a multiple composition fiber having a cross section that is one of sheath/core, “islands in the sea” with a circular cross-section, tri-lobal cross-section, and multi-lobal cross-section. 
     
     
         9 . The composite fiber according to  claim 1 , comprising at least two structural parts respectively containing different materials. 
     
     
         10 . The composite fiber according to  claim 1 , wherein the fiber has a diameter between 5 and 100 microns. 
     
     
         11 . The composite fiber according to  claim 10 , wherein the fiber has a diameter between 10 and 30 microns. 
     
     
         12 . A sheet material comprising:
 a composite fiber containing a particle component and a polymer component, wherein discrete particles in the particle component impart to the composite fiber a specific gravity of at least 2.0;   wherein the fiber is formed into a sheet and includes at least one of thread, solid nonwoven material, nonwoven material with perforations, mesh, and felt comprising said composite fiber.   
     
     
         13 . The sheet material according to  claim 12 , wherein the sheet is a multi-layer construct comprising plural distinct layers, wherein a given said layer differs in properties from at least one other said layer, and that includes at least one of thread, solid nonwoven material, nonwoven material with perforations, mesh, and felt comprising a fiber distinct from said composite fiber. 
     
     
         14 . The sheet material according to  claim 12 , further comprising a coating of particles on the sheet. 
     
     
         15 . The sheet material according to  claim 12 , further comprising as least one of a layer, laminate and coating imparting at least one of non-stick properties, reduced coefficient of friction, chemical and corrosion resistance, electrical insulation, wear resistance, lubrication, heat-resistance, and water resistance. 
     
     
         16 . The sheet material according to  claim 12 , wherein the composite fiber is one of knit and woven fabric to form a fabric. 
     
     
         17 . The sheet material according to  claim 12 , comprising plural distinct layers, wherein a given said layer differs in properties from at least one other said layer. 
     
     
         18 . The sheet material according to  claim 12 , wherein the fabric is structured to receive objects that are at least temporarily affixed. 
     
     
         19 . The sheet material according to  claim 18 , wherein the objects are one of pocketed, zipped in and sewn in. 
     
     
         20 . The sheet material according to  claim 12 , further comprising weights affixed to the fabric.