Fibers and other constructs treated with diatomite particles

Abstract

Constructs consisting of diatomized fibers, filaments, yarns, woven and non-woven textiles, fiber-based films, mats, and membranes, other constructs and finished products made from the foregoing. The inventive subject matter is particularly directed to apparel products and molded footwear outsoles, and other molded or textile-based products, wherein a plurality of diatomite particles embedded in the surface of a construct impart desired functionalities, such as moisture management, odor control, or traction or grip enhancement, water and dirt repellency, and wear resistance.

1 . A diatomized construct, comprising a fiber, filament or yarn having a plurality of diatomite particles embedded in the surface of the construct generally uniformly over a selected portion of the surface area of the construct. 
     
     
         2 . The diatomized construct, of  claim 1  wherein the particles generally uniformly cover about 1-10% of the construct surface. 
     
     
         3 . The construct of  claim 1  wherein the particles generally uniformly cover 10-30% or thereabout of the construct surface. 
     
     
         4 . The construct of  claim 1  wherein the particles generally uniformly cover about 30% or more of the construct surface. 
     
     
         5 . The construct of  claim 1  wherein the construct comprises a thermoplastic material. 
     
     
         6 . (canceled) 
     
     
         7 . The construct of  claim 1  wherein the diatomite particles are present at 0.1% to 5% by fiber weight or thereabout in a thermoplastic material forming the construct. 
     
     
         8 . (canceled) 
     
     
         9 . The construct of  claim 1  wherein the particles have an average size of less than 5 μm or thereabout. 
     
     
         10 . The construct of  claim 1  wherein the particles have an average size of more than 200 μm or thereabout. 
     
     
         11 . The construct of  claim 1  further comprising a plurality of the diatomized fibers, filaments, and/or yarns arranged in a lattice structure. 
     
     
         12 . The textile of  claim 11  wherein the lattice comprises a woven or knit structure. 
     
     
         13 .- 14 . (canceled) 
     
     
         15 . The diatomized construct of  claim 11  wherein the structure comprises a first layer and further comprising a second adjacent knit or woven layer in a discrete lattice comprising fibers, filaments, or yarns. 
     
     
         16 . The diatomized construct of  claim 15  wherein one or both of the first and second layers comprises a layer of fully or partially melted thermoplastic fibers, filaments or yarns that are fused to the other layer. 
     
     
         17 . The construct of  claim 11  wherein a plurality of the diatomite particles have been chemically modified or treated to provide functionality not inherent in the particles. 
     
     
         18 . (canceled) 
     
     
         19 . The construct of  claim 18  wherein the diatomite particles have been chemically modified or treated to render them relatively more hydrophobic than in their inherent state. 
     
     
         20 .- 28 . (canceled) 
     
     
         29 . A method of forming a fiber, comprising dispersing diatomite particles into a solid or melted thermoplastic feedstock material and spinning the mixture into fibers. 
     
     
         30 . (canceled) 
     
     
         31 . The method of  claim 29  further comprising collecting the fibers as continuous lengths of fiber. 
     
     
         32 . The method of  claim 31  wherein the continuous length fibers are made into staple fibers. 
     
     
         33 . The method of  claim 29  comprising forming the collected fibers into yarns or other multifilament structures. 
     
     
         34 . (canceled) 
     
     
         35 . The construct of  claim 11 , wherein the construct comprises a yarn or another assembly of multifilaments wherein the multifilament structure has a ratio of denier/filament number of 0.25 to 2. 
     
     
         36 . (canceled) 
     
     
         37 . The construct of  claim 11  wherein the lattice structure has a diatomized surface topology configured to provide a Lotus Effect. 
     
     
         38 . The construct of  claim 1  wherein the lattice surface has a diatomized surface comprising a base material and a plurality of discrete agglomerations of diatomite particles embedded in or applied to the base material and exposed at the surface of the base material. 
     
     
         39 . The construct of  claim 38  further comprising a plurality of non-diatomite sand or sand-like embedded in or applied to the base material and exposed at the surface of the base material.