Forcespinning of fibers and filaments

Abstract

Among other things, the inventive subject matter generally relates to systems and methods for collecting fibers of any scale in agglomerations of generally parallel strands for use in forming yarns, for example.

1 . A method of producing a waterproof/breathable membrane, comprising:
 forcing a fluid, fiber-forming material through at least one outlet port disposed in an apparatus configured to expel a jet of the material, the apparatus configured to provide a jet that is fine enough to solidify on a collector as a superfine fiber, the primary expulsion force of the jet being other than an applied electrical field; and   expelling the material until a web of superfine fibers is formed on the collector;   working the web to a density and porosity sufficient to provide waterproofness and breathability to a selected standard.   
     
     
         2 . The method of  claim 2  wherein the web comprises nanoscale fibers that are worked to a thickness of at least about 7 micrometers. 
     
     
         3 . The method of  claim 2  wherein the web has an average pore size of at least 250 nm. 
     
     
         4 . The method of  claim 2  wherein the thickness of the web is between about 7 to about 50 micrometers. 
     
     
         5 . The method of  claim 1  wherein the average pore size is between about 250 to about 1500 nm. 
     
     
         6 . The method of  claim 4  wherein the average pore size is between about 250 to about 1500 nm and the web thickness is between about 7 to about 50 micrometers. 
     
     
         7 . The method of any of the claims wherein the average fiber diameter is less than 1000 nm. 
     
     
         8 . The method of any of the claims wherein the average fiber diameter is less than 1000 nm. 
     
     
         9 . The method of any of the claims wherein the average fiber diameter is less than 500 nm. 
     
     
         10 . The method of any of the claims wherein the average fiber diameter is less than 100 nm. 
     
     
         11 . The method of any of the foregoing claims wherein the average fiber diameter is less than 50 nm. 
     
     
         12 . The method of any of the claims wherein the average fiber has an aspect ratio of at least 100. 
     
     
         13 . The method of any of the claims wherein the fiber-forming material comprises PTFE or a polyurethane-based material. 
     
     
         14 . The method of any of the claims wherein the apparatus comprises a force-spinning apparatus and centrifugal force is the primary force that expels the fiber-forming material from the at one or more outlet ports. 
     
     
         15 . The method of any of the claims wherein the collector of the fibers comprises a component of an end product or a 3D mold or other form for an end product. 
     
     
         16 . The method of  claim 15  wherein the end product or component thereof is a garment or apparel item, e.g., a jacket or pants; an item of footwear, e.g., a shoe or sock; headwear, e.g., a soft cap, a brimmed or visored hat, or a facemask; an item of outdoor equipment, e.g., a sleeping bag or shell for a sleeping bags, a blankets, a tent, a tarp or other cover; or an item of luggage or pack, e.g., a soft-sided bag, a backpack, a waist pack, a suitcase, a duffel bag, a bike messenger bag and other bags, or a briefcase. 
     
     
         17 . The method of any claim wherein the fibers are collected onto a sheet of material to form a bilayer of material. 
     
     
         18 . The method of  claim 1  wherein the sheet of material comprises a synthetic polymer material, such as a nylon, polyester, or polyethylene based material or a natural material such as wool or leather, plant-based biomaterials, or blends of the foregoing. 
     
     
         19 . The method of  claim 15  wherein the collector comprises a mold that supports a component of the end product and the fibers are deposited on the mold and/or the component. 
     
     
         20 . The method of any of the claims wherein the collector comprises a last for a shoe or a mold for a glove. 
     
     
         21 . The method of  claim 20  wherein the last supports another component for a shoe, such as a component of an outsole. 
     
     
         22 . The method of  claim 19  or  20  wherein the fibers are deposited so as to form an integral unit with the component. 
     
     
         23 . The method of  claim 15  wherein the fibers are collected on a 3D mold or structure that represents an article of apparel or part thereof, e.g., a sleeve or pant leg, the collected fiber providing a seamless enclosure for an area of the intended user's body. 
     
     
         24 . The method of any of the claims wherein the collector disposed on a continuous belt or other transport that may be selectably moved across the outlet port area for the apparatus. 
     
     
         25 . The method of any of the claims wherein the apparatus includes an associated fiber-directing system for directing jets or fiber on the collector. 
     
     
         26 . The method of  claim 25  wherein the fiber-directing system is configured to provide a directing airflow to the collector (e.g., a fan or vacuum). 
     
     
         27 . The method of any of the claims comprising the further steps of assembling the web to other components of an end product or depositing on the web other materials for use in the end product, such as those end products in  claim 16 . 
     
     
         28 . The method of any of the claims wherein the assembling is done in-line with the web formation. 
     
     
         29 . The method of any of the claims wherein a plurality of different fiber types are expelled from the outlet port(s) of the apparatus to form a heterogeneous web of fibers, the fibers differing in material composition and/or structural properties. 
     
     
         30 . A web of superfine fibers according to the fiber or web parameters or any combination thereof of any of  claims 2 - 13 . 
     
     
         31 . Any combination of fiber material blends and fiber diameters/geometries according to any of  claims 1 - 3  wherein the fiber blends are produced by jet extrusion via multiple spinnerets, the spinnerets providing a plurality of outlet ports, each outlet port intended for a predetermined fiber-type, the blend being collected as a web on another layer of fabric or a composite of fabric layers, which layers may or may not incorporate a combination of different fiber material blends. 
     
     
         32 . Related apparatus and post-web formation processing into end products. 
     
     
         33 . A construct of fibers that substantially mimics down plumules or synthetic insulative batting. 
     
     
         34 . The construct of  claim 33  wherein the construct has a fill power equivalent of 450 to 1,000. 
     
     
         35 . The construct of  claim 34  where in the fill power equivalent is at least 650. 
     
     
         36 . A method of producing a filament, comprising an agglomeration of fibers oriented in the same direction over a predetermined length, the method steps comprising:
 forcing a fluid, fiber-forming material through at least one outlet port disposed in an apparatus configured to expel a jet of the material, the apparatus configured to provide a jet that is fine enough to solidify on a collector as a superfine fiber, the primary expulsion force being other than an applied electrical field;   expelling the material until a web of superfine fibers is formed on the collector; and   working the web to a density and porosity sufficient to provide waterproofness and breathability to a selected standard.   
     
     
         37 . A force spinning system, comprising: a spinneret with an associated axis of rotation, a fiber collector spaced apart from the spinneret, the collector having a spinnable surface for receiving a fiber, the surface having an associated axis, and the collector being spinnable about the axis, the collector being oriented with its axis generally parallel or perpendicular to the axis of rotation of the spinneret and positioned relative to the spinneret so that a stream of fiber material ejected from the spinneret is received on the collector and is spoolable onto the collector with the fibers oriented generally in parallel. 
     
     
         38 . The system of  claim 37  wherein the collector is disposed with its axis generally parallel to the axis of spinneret and wherein the system is configured so that collector is orbital around the spinneret, or, alternatively, the spinneret is orbital around the collector, in which case the collector may not spin around its own axis. 
     
     
         39 . The system of  claim 37  wherein the collector is disposed below and centered generally under the axis of rotation of the spinneret. 
     
     
         40 . A force spinning method, comprising: operating a spinneret with an associated axis of rotation, ejecting from the spinneret a stream of fiber-forming material, and collecting the streaming material on a collector so that the fibers are oriented generally in parallel. 
     
     
         41 . The method of  claim 40  wherein the collector has a relative orbital rotation about the spinneret and/or around its own axis so as to collect the fibers in the generally parallel orientation. 
     
     
         42 . The system or method of  claim 36  wherein the system is configured to produce filaments in the range of 1 to 300 denier. 
     
     
         43 . The system or method of any claim wherein the system is configured to produce fibers with aspect ratios of at least 100, 500, 1000, 5000 or higher relative to the fiber diameters of any claim and wherein the collected fibers have lengths of at least 1 meter, 10 meters, or more. 
     
     
         44 . The system or method of any claim wherein the system or method is configured or performed to produce fibers or filaments suitable for use in the weaving or knitting of textiles, particularly textiles suitable for use in making garments and apparel. 
     
     
         45 . A textile made from a yarn or other filament comprising a collected fiber from any of the foregoing claims to a system or a method. 
     
     
         46 . A garment or apparel item made from the textile of  claim 45 . 
     
     
         47 . A collected fiber made according to any method or using any system of any  claims 36 - 45 .