PRODUCTION OF FABRIC WITH ENHANCED THERMOREGULATION PROPERTIES

Information

  • Patent Application
  • 20250137171
  • Publication Number
    20250137171
  • Date Filed
    October 23, 2024
    9 months ago
  • Date Published
    May 01, 2025
    3 months ago
  • Inventors
    • Kolbe; Chris (Elm Grove, WI, US)
    • Arkins; Christian (Madison, CT, US)
    • Cheung; Hing Lam
    • Atkinson; James (Venice Beach, CA, US)
  • Original Assignees
Abstract
Compositions of matter, methods, and systems for producing fibers, yarns, and fabrics with enhanced thermoregulation properties are provided. The composition may be created from a cellulose solution derived from natural sources, into which nano-sized phase change materials and high-specific heat minerals are incorporated. These additives form a mesoporous structure within the fiber, enabling the capture and retention of the nanomaterials. The method involves spinning this composite solution into yarn, which can be blended with additional fibers to produce a bespoke yarn. This yarn can then be knitted or woven into fabrics that maintain thermoregulation.
Description
BACKGROUND OF THE INVENTION
1. Field of the Disclosure

The present disclosure is generally related to producing fabric with enhanced thermoregulation properties.


2. Description of the Related Art

Many presently available textiles fail to provide consistent thermal regulation, leading to discomfort in varying environmental conditions, particularly during physical activities or warm climates. Traditional fabrics also often lack effective antimicrobial properties, resulting in the growth of bacteria and odors, especially in activewear and garments worn for extended periods. Further, the production of conventional synthetic fibers and fabrics often has a significant environmental footprint, including use of non-renewable resources and generation of micro plastic waste. Many performance fabrics also contain harmful chemicals and dyes that can be leached from the fabrics and absorbed into the skin of the wearer, particularly in active and sportswear. Lastly, synthetic fabrics used in everyday wear and performance garments can suffer from yarn pilling and loss of aesthetic and functional properties after chemicals treatments wash out over a few laundry cycles, reducing their overall lifespan and requiring more frequent replacement. There is a growing consumer demand for textiles that combine sustainability with enhanced natural functionality, such as cooling effects, elasticity, and durability, without compromising comfort and aesthetic appeal. Thus, there is a need in the prior art for producing fabric with enhanced thermoregulation properties.


SUMMARY OF THE CLAIMED INVENTION

Embodiments of the present invention include a composition of matter, method, and system for producing fibers, yarns, and fabrics with enhanced thermoregulation properties. The composition may be created from a cellulose solution derived from natural sources, into which nano-sized phase change materials and high-specific heat minerals are incorporated. These additives form a mesoporous structure within the fiber, enabling the capture and retention of the nanomaterials. Production of the fabric may include spinning the composite solution into yarn, which can be blended with additional fibers to produce a bespoke yarn. This yarn can then be knitted or woven into fabrics that maintain thermoregulation.





BRIEF DESCRIPTIONS OF THE DRAWINGS


FIG. 1 is a flowchart that illustrates an exemplary method of producing fabric with enhanced thermoregulation properties.



FIG. 2 is a flowchart that illustrates an exemplary mixing process.



FIG. 3 is a flowchart that illustrates an exemplary yarn-spinning process.



FIG. 4 is a flowchart that illustrates an exemplary fabric production process.



FIGS. 5A and 5B respectively illustrate microscopic views of an original surface state of the base material and the base material surface coated with phase change materials.





DETAILED DESCRIPTION

Embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which example embodiments are shown. Embodiments of the claims may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.



FIG. 1 illustrates a method for producing fabric with enhanced thermoregulation properties. The method produces a finished fabric 102 that cools the skin, resists odor, increases blood circulation, and is soft, comfortable, and biodegradable, which is an alternative to synthetic materials. The finished fabric 102 is created by blending a viscous solution that includes a base material 126, a phase change material 128, a high specific heat material 120, and chitosan 122. The solution is spun into yarn 108, which is then combined with other yarn 106, such as recycled spandex, to produce a special blend of knitted fabrics to create the finished fabric 102.


A base material 126 may be a mesoporous material with high nanopore porosity, such as diatomaceous earth, sepiolite, zeolite, and kaolinite. In some embodiments, a mesoporous material or super nanoporous material may be a nanoporous material containing pores with diameters between 2 and 50 nm.


Phase change materials 128 may include water, eicosane, heneicosane, octadecane, nonadecane, vanadium dioxide, or VO2, etc. In some embodiments, phase change materials 128 may either be dispersed or dissolved into the base material's 126 pores. Phase change materials are nano-sized to effectively integrate into the base material.


An embedded base material 124 is produced by adding one or more phase change materials 126 to the base material 126. The embedded base material 124 may be composed of a nano-engineered structure designed to achieve functional cooling and antimicrobial benefits within a fiber. In some embodiments, the core of the composition may be the mesoporous base material 124 characterized by its high nanopore porosity, which serves as the matrix for embedding phase change materials 128. In some embodiments, the phase change materials 128 may be distributed within the pores of the base material 126 in their solid or liquid state. The dispersion may be achieved through techniques such as impregnation or encapsulation to ensure that the phase change materials 128 are securely lodged within the mesoporous structure allowing for controlled thermal exchanges with the surrounding environment as the fiber is subjected to temperature variations. In some embodiments, the phase change materials 128 may be dissolved into the base material's 126 pores using solvents or other suitable carriers. For example, upon drying or curing, the solvent evaporates, leaving the phase change material 128 embedded within the nanopores and ensuring intimate contact between the phase change material 128 and the base material 126, which optimizes the thermal conductivity and phase change efficiency of the fiber.


One or more high-specific heat materials 120 may be added to the embedded base material 124. The high-specific heat material 120 may be jade, diatomaceous earth, sepiolite, talc, zeolite, kaolinite, monazite, mica, serpentine, basalt, and oxides of silicon, aluminum, magnesium, sodium, calcium, phosphides, nitrides, silicates, etc.


Chitosan 122 may further be added to the embedded base material 124. Chitosan 112 may be a biopolymer derived from chitin, which is found in the exoskeletons of crustaceans like shrimp and crabs.


At step 118, the embedded base material 124, high specific heat material 120, and chitosan 122 may be mixed, which may be a process of distributing individual particles, molecules, or components into one another to achieve uniform composition, properties, and characteristics throughout the mixture. In some embodiments, the phase change material 128 embedded base material 126, the high specific heat material 120, and chitosan 122 powder are completely dried before mixing 118. Mixing 118 may produce compound powder 116.


A compound powder 116 may be a finely divided solid material composed of the phase change material 128, base material 126, the high specific heat material 120, and chitosan 122 that are homogeneously mixed at the particulate level. In some embodiments, the components of a compound powder 116 may be combined through a controlled mixing 118 process, ensuring uniform distribution of each constituent within the powder matrix. The compound powder 116 may be processed to produce a cooling fiber 114.


At step 130, a cooling fiber 114 may be formed by processing the compound powder 116 through techniques such as spinning or extrusion, where the compound powder 116 may be added into a cellulose source 132 to produce a viscous solution to enable the formation of continuous strands. The cellulose source 132 may be derived from cotton, paper waste, wood pulp, or recycled textile materials. In some embodiments, the individual particles within the powder 116, including phase change materials 128 embedded in the base material 126, high specific heat materials 120, and chitosan 122, are distributed along the length of the fiber. The cooling fiber 114 may be a composite fiber engineered to regulate temperature by integrating materials with thermal management properties, such as phase change materials 128 and high-specific heat materials 120. In some embodiments, the components may be uniformly distributed within the cooling fiber 114, allowing it to absorb, store, and release heat efficiently.


The cooling fiber 114 may undergo yarn spinning at step 110, which may be the process of converting raw fibers, such as the cooling fibers 114 and other fibers 112, into continuous strands of yarn through mechanical or chemical means and may involve several stages, including fiber preparation, carding, drawing, roving, and final spinning. In some embodiments, individual fibers may be aligned, drawn out, and twisted together to form a cohesive, uniform yarn 108 with specific properties such as thermoregulation, odor resistance, increased blood circulation, etc. In some embodiments, the degree of twist, fiber type, and spinning method, such as ring spinning, open-end spinning, or air-jet spinning, may be controlled to produce yarns 108 suitable for various textile applications.


The product of yarn spinning process is yarn 108, which may contain the cooling fiber 114 and other fibers 112. Other fibers 112 may also be created from a separate yarn spinning 110 process. Other fibers 112 may be Supima® cotton, Regen Cotton, Organic Cotton, Good Earth Cotton, wool, linen, hemp, Tencel Modal, Tencel Lyocell, and other bio-synthetic fibers.


Yarn 108 may undergo fabric production further described in FIG. 4 to be transformed into fabric 102. finished fabric 102 ready for use in various applications, The finished fabric is ready to use in various applications, such as clothing, upholstery, and industrial textiles. In some embodiments, fabric production 104 may include knitting, weaving, dyeing, finishing, etc. In some embodiments, knitting or weaving may be the interlacing or interloping of yarns to form fabric structures. Some embodiments include dyeing yarn or fabrics, to color to yarns or fabrics. In some embodiments, finishing may be the treatment processes applied to the fabric to enhance its properties, such as softening, shrinking, or adding water-repellent characteristics. During the fabric production, yarn 108 may be interloped or blended with other yarn 106. Other yarns 106 may be recycled spandex or yarns made of bio-synthetics fibers.



FIG. 2 illustrates an embodiment of the mixing process 210, which produces a compound powder 212 that is turned into a cooling fiber 214.


The phase change material 200 may be water, eicosane, heneicosane, octadecane, nonadecane, vanadium dioxide or VO2, etc. In some embodiments, phase change materials 200 may either be dispersed or dissolved into the base material's 202 pores. In some embodiments, the phase change materials 200 may be selected based on their specific phase change temperatures and thermal storage capacities, which are tailored to the desired cooling performance of the fiber.


The base material 202 may be a mesoporous material with high nanopore porosity, such as diatomaceous earth, sepiolite, zeolite, and kaolinite. In some embodiments, the base materials 202 may contain an extensive network of nanopores, which allows for the efficient encapsulation and stabilization of functional additives. In some embodiments, a mesoporous material or super nanoporous material may be a nanoporous material containing pores with diameters between 2 and 50 nm. In some embodiments, the high porosity of the base material 202 ensures that the embedded phase change materials 200 are well-distributed within the fiber 214, enabling uniform thermal regulation and enhanced mechanical stability.


The embedded base material 204 may be composed of a nano-engineered structure designed to achieve functional cooling and antimicrobial benefits within the cooling fiber 214. In some embodiments, the core of the composition may be the mesoporous base material 202 characterized by its high nanopore porosity, which serves as the matrix for embedding phase change materials 200. In some embodiments, the phase change materials 200 may be distributed within the pores of the base material 202 in their solid or liquid state. The dispersion may be achieved through techniques such as impregnation or encapsulation to ensure that the phase change materials 200 are securely lodged within the mesoporous structure allowing for controlled thermal exchanges with the surrounding environment as the cooling fiber 214 is subjected to temperature variations. In some embodiments, the phase change materials 200 may be dissolved into the base material's 202 pores using solvents or other suitable carriers. For example, upon drying or curing, the solvent evaporates, leaving the phase change material 200 embedded within the nanopores and ensuring intimate contact between the phase change material 200 and the base material 202. This optimizes the thermal conductivity and phase change efficiency of the cooling fiber 214. The high specific heat materials 206 may be jade, diatomaceous earth, sepiolite, talc, zeolite, kaolinite, monazite, mica, serpentine, basalt, and oxides of silicon, aluminum, magnesium, sodium, calcium, phosphides, nitrides, silicates, etc.


In some embodiments, the high specific heat materials 206 may absorb and retain significant amounts of heat without undergoing substantial temperature changes. In some embodiments, the high specific heat materials 206 may include a range of porous minerals and clays, each contributing unique thermal and moisture management properties to the composite. For example, Jade has high thermal conductivity and specific heat, allowing it to absorb body heat and slowly release it, creating a cooling sensation. Sepiolite has a porous structure that enhances its ability to absorb moisture and contributes to the fiber's 214 overall cooling and antimicrobial effects. Talc has fine, smooth particles that provide additional moisture absorption and enhance the softness of the fabric 214. Other high-specific heat materials 206, like zeolite, kaolinite, and mica, may further contribute to the composite's functionality by offering varied thermal and adsorption properties, depending on their specific mineral composition.


The chitosan 208 may be a biopolymer derived from chitin, which is found in the exoskeletons of crustaceans like shrimp and crabs, and contains unique properties, which include biocompatibility, biodegradability, and inherent antimicrobial activity. Chitosan 208 has natural antimicrobial properties, making it effective at inhibiting the growth of bacteria, fungi, and other microorganisms. In some embodiments, the antimicrobial properties in chitosan 208 may help maintain hygiene and reduce odor caused by microbial growth.


The mixing process 210 may produce a uniform compound powder 212 with nano-sized particles, which may be effectively integrated into various fibers. The mixing process 210 may include micronizing the embedded base material 204, high specific heat materials 206, and chitosan 208. For example, micronizing may be the process of reducing the particle size of the materials to the nanometer or micrometer range, such as 100 nm to 2000 nm in this context. In some embodiments, the micronizing process may be achieved through high-energy milling techniques such as jet milling, ball milling, cryogenic milling, etc. In some embodiments, jet milling may be the process of pulverizing the material by the high-speed impact of particles against each other in a high-pressure air stream. In some embodiments, ball milling may be the process of grinding down the materials by rolling and impacting in a rotating cylinder filled with hard spheres, or balls. In some embodiments, cryogenic milling may be the process of cooling the materials to low temperatures using liquid nitrogen before milling, which prevents agglomeration and preserves the structure of heat-sensitive components like chitosan 208. The base material 202 with embedded phase change materials 200, high specific heat materials 206, and chitosan 208 are combined to create a homogeneous compound powder 212.


In some embodiments, the mixing process 210 may be high shear mixing, ultrasonic mixing, stirring dispersion, grinding dispersion, etc. For example, high-shear mixers may use rotating blades or impellers that create intense shear forces, breaking down any agglomerates and ensuring even dispersion of the components. Ultrasonic mixers may use high-frequency sound waves to agitate the particles in the mixture and the ultrasonic waves may cause cavitation bubbles to form and collapse, creating strong shear forces that help to evenly distribute particles throughout the mixture. Stirring dispersion may involve using a mechanical stirrer to blend the components at controlled speeds, and depending on the viscosity of the mixture, different types of stirrers, such as paddle, anchor, or turbine stirrers, may be used to achieve thorough mixing. Grinding dispersion may involve combining the materials with grinding media, such as beads, in a mill, where the grinding action helps to break down any remaining agglomerates and ensures even distribution.


In some embodiments, the compound powder 212 may be subjected to a final homogenization step after mixing to ensure that all components are uniformly distributed at the molecular or nano level. In some embodiments, the compound powder 212 may be tested for homogeneity, particle size distribution, and the evenness of the embedded phase change materials 200. The compound powder 212 may be designed to enhance the cooling and antimicrobial properties of various fibers and textiles. The compound powder 212 may be created through the micronization and blending of a mesoporous base material 202 embedded with phase change materials 200, high-specific heat materials 206, and chitosan 208. The base material 202, such as diatomaceous earth or sepiolite, features a high nanopore porosity, allowing it to effectively house phase change materials 200, such as eicosane or vanadium dioxide, which absorb and release heat to regulate temperature dynamically. The high-specific heat materials 206, including jade, zeolite, and various metal oxides, may further contribute to thermal management by absorbing and retaining heat without significant temperature changes, while also managing moisture through their porous structures. Chitosan 208, a biopolymer with natural antimicrobial properties, may be incorporated to inhibit microbial growth. The compound powder 212 may be micronized to a particle size range of 100 to 2000 nanometers, ensuring uniform distribution within fibers.


The cooling fiber 214 formed from the compound powder 212 may be designed to offer superior thermal regulation and antimicrobial properties, making it ideal for use in a wide range of textile applications. The cooling fiber 214 may be produced by integrating the compound powder 212, composed of a mesoporous base material 202 embedded with phase change materials 200, high specific heat materials 206, and chitosan 208, into a fiber matrix during the fiber manufacturing process. The result is a cooling fiber 214 that provides effective cooling and moisture management and also resists microbial growth, enhancing comfort, hygiene, and performance in the final textile products. In some embodiments, the cooling fiber 214 may provide effective thermal management through the embedded phase change material 200, which absorbs excess heat and undergoes phase transitions to regulate temperature. In some embodiments, the high specific heat materials 206 may further stabilize the temperature by absorbing and slowly releasing heat. In some embodiments, the cooling fiber's 214 ability to absorb and manage moisture may be enhanced by the porous structures of the high specific heat materials 206. In some embodiments, the chitosan 208 may provide natural antimicrobial properties, helping to prevent the growth of bacteria and fungi on the fiber.


In some embodiments, the cooling fiber 214 may be formed by a viscose spinning process, melt spinning process, wet spinning process, etc. The viscose spinning process may involve blending the compound powder 212 with viscose pulp, which may be derived from cotton, paper waste, wood pulp, or recycled textile materials. The mixture may then be dissolved in a viscose solution, which may be spun into cooling fibers 214 using a spinning machine. In some embodiments, the solution may be a cellulose solution, viscose solution, polyester solution, nylon solution, polylactic acid or PLA solution, etc. The spinning solution may be extruded through spinnerets into an acidic coagulation bath, where it solidifies into continuous filaments. The compound powder 214 may be uniformly distributed throughout the viscose matrix, ensuring that each fiber 214 strand has cooling, moisture management, and antimicrobial properties. The resulting viscose fibers may then be washed, stretched, and dried to achieve the desired mechanical properties. In the melt spinning process, the compound powder 212 may be mixed with a molten polymer, such as polyester or nylon, creating a homogeneous blend, and the blend may then be extruded through a spinneret to form continuous filaments. As the filaments cool, they solidify into fibers, with the compound powder 212 evenly dispersed throughout. The phase change material 200 embedded in the base material 202 within the fiber 214 provides thermal regulation, while the high specific heat materials 206 and chitosan 208 may contribute to moisture management and antimicrobial properties. In wet spinning, the compound powder 212 may be mixed with a polymer solution, such as a cellulose derivative or a synthetic polymer dissolved in a solvent, and the mixture may be extruded through spinnerets into a coagulation bath, where the polymer precipitates into solid fibers. The coagulation process ensures that the compound powder 212 may be uniformly distributed within the fiber 214. The fibers 214 may be stretched, washed, and dried, resulting in a finished product that retains the cooling and antimicrobial benefits of the compound powder 212.



FIG. 3 illustrates an embodiment of the yarn-spinning process. The cooling fiber 300 formed from the compound powder 116 may be designed to offer superior thermal regulation and antimicrobial properties, making it ideal for use in a wide range of textile applications. The cooling fiber 300 may be produced by integrating the compound powder 116, composed of a mesoporous base material 126 embedded with phase change materials 128, high specific heat materials 120, and chitosan 122, into a fiber matrix during the fiber manufacturing process. The result is a cooling fiber 300 that provides effective cooling and moisture management and also resists microbial growth, enhancing comfort, hygiene, and performance in the final textile products. In some embodiments, the cooling fiber 300 may provide effective thermal management through the embedded phase change material 128, which absorbs excess heat and undergoes phase transitions to regulate temperature. In some embodiments, the high specific heat materials 120 may further stabilize the temperature by absorbing and slowly releasing heat. In some embodiments, the cooling fiber's 300 ability to absorb and manage moisture may be enhanced by the porous structures of the high specific heat materials 120 and the moisture-retaining properties of chitosan 122. In some embodiments, the chitosan 122 may provide natural antimicrobial properties, helping to prevent the growth of bacteria and fungi on the fiber.


In some embodiments, the cooling fiber 300 may be formed by a viscose spinning process, melt spinning process, wet spinning process, etc. The viscose spinning process may involve blending the compound powder 116 with viscose pulp, which may be derived from cotton, paper waste, wood pulp, or recycled textile materials. The mixture may then be dissolved in a viscose solution, which may be spun into cooling fibers 300 using a spinning machine. The spinning solution may be extruded through spinnerets into an acidic coagulation bath, where it solidifies into continuous filaments. The compound powder 116 may be uniformly distributed throughout the viscose matrix, ensuring that each fiber 300 strand has cooling, moisture management, and antimicrobial properties. The resulting viscose fibers may then be washed, stretched, and dried to achieve the desired mechanical properties. The blend may then be extruded through a spinneret to form continuous filaments. As the filaments cool, they solidify into fibers, with the compound powder 116 evenly dispersed throughout. The phase change material 128 embedded in the base material 126 within the fiber 300 provides thermal regulation. In contrast, the high specific heat materials 120 and chitosan 122 may contribute to moisture management and antimicrobial properties. In wet spinning, the compound powder 116 may be mixed with a polymer solution, such as a cellulose derivative, and the mixture may be extruded through spinnerets into a coagulation bath, where the polymer precipitates into solid fibers. The coagulation process ensures that the compound powder 116 may be uniformly distributed within the fiber 300. The fiber 300 may be stretched, washed, and dried, resulting in a finished product that retains the cooling and antimicrobial benefits of the compound powder 116.


The yarn spinning 304 process may produce yarn 306 with specific properties, such as strength, elasticity, softness, and functionality, in which individual fibers are drawn out, twisted, and combined to form continuous strands of yarn 306. The process begins with the preparation of various fibers, such as cooling fibers 300 and other fibers 302. The other fibers 302 may be Supima® cotton, Regen Cotton, Organic Cotton, Good Earth Cotton, wool, linen, hemp, Tencel Modal, Tencel Lyocell, and other bio-synthetic fibers. In some embodiments, the other fibers 302 may include Supima® cotton, which is a premium, extra-long-staple cotton known for its superior softness, strength, and durability. Its longer fibers result in smoother, more resilient yarns that are less prone to pilling, making it ideal for high-quality textiles that require both comfort and longevity. In some embodiments, the other fibers 302 may include Regen Cotton, which is a form of regenerated cotton and is an eco-friendly option that reuses cotton waste, offering sustainability without compromising on the softness and breathability typical of cotton fibers. In some embodiments, the other fibers 302 may include Organic Cotton, which shares the same natural comfort and breathability as traditional cotton but is grown without synthetic pesticides or fertilizers, making it a more environmentally friendly choice. In some embodiments, other fibers 302 may include Good Earth Cotton, wool, linen, hemp, Tencel Modal, and Tencel Lyocell. These may be blended with the cooling fibers 300 to further enhance the fabric's properties.


The fibers 300 and other fibers 302 may be blended in specific proportions to achieve the desired balance of properties in the final yarn 306. For example, Supima® cotton may be blended for its softness and durability. In some embodiments, the fibers 300 and other fibers 302 may undergo carding, which is a process that disentangles and aligns the fibers 300 and other fibers 302 to form a continuous web or sliver. Carding ensures that the fibers are evenly distributed and aligned in the same direction to ensure the consistency of the yarn 306. In some embodiments, a combing process may be performed, where shorter fibers are removed, and the remaining fibers 300 and other fibers 302 may be further aligned and parallelized to enhance the smoothness and strength of the yarn 306 by ensuring that only the longest and most uniform fibers are used. In some embodiments, the carded or combed slivers are then fed into a drawing frame, where they are stretched and elongated. Drawing combines several slivers and pulls them through a series of rollers, which progressively reduce the thickness of the fiber bundle while maintaining alignment. In some embodiments, after drawing, the fiber bundle is transformed into roving, a slightly twisted strand that is finer and stronger than the sliver.


The yarn spinning 304 processes may include spinning, such as ring spinning, open-end spinning, air-jet spinning, etc. For example, in ring spinning, the roving is drawn out to the final desired thickness and then twisted to form yarn 306. In some embodiments, the degree of twist may be carefully controlled, as it influences the yarn's strength, elasticity, and texture. In some embodiments, the spinning process for cooling fibers 300 may require special attention to ensure that the phase change materials 128 and other additives remain evenly distributed throughout the yarn 306. In some embodiments, open-end spinning may be performed in which the fibers are fed into a rotating rotor, twisted, and then wound onto a bobbin. In some embodiments, air-jet spinning may be performed, which uses high-speed air to twist the fibers into yarn 306.


After spinning, the yarn 306 may be wound onto spools or cones. In some embodiments, the yarn 306 may be checked for any inconsistencies or defects, such as uneven thickness or weak spots, which are removed. In some embodiments, the yarn 306 may undergo a cleaning process to remove any residual impurities or short fibers that could affect the performance or appearance of the fabric. For example, in the case of yarns containing cooling fibers, any residue that might interfere with the thermal or antimicrobial functions is removed. The yarn 306 produced through the yarn spinning 304 process may be a blend of cooling fibers 300 and other fibers 302. The integration of the cooling fibers 300 ensures that the yarn 306 offers dynamic thermal regulation, absorbing and releasing heat to maintain a comfortable temperature.


In some embodiments, different ratios of cooling fibers 300 and other fibers 302 in yarn 306 may be tailored to meet the specific needs of various textile applications. For activewear, a yarn 306 blend may consist of 50% cooling fiber 300, 40% Supima® cotton, and 10% additional performance fibers, which may ensure effective thermal regulation, softness, durability, and flexibility, making it ideal for high-performance sportswear. For everyday comfort clothing, a blend may include 20% cooling fiber 300, 60% organic cotton, and 20% linen, which may provide a soft, natural feel with subtle cooling effects, enhanced breathability, and slight stretch for added comfort. In performance sportswear, a yarn 306 might be composed of 60% cooling fiber 300, 25% Regen Cotton, and 15% recycled spandex, providing a balance between cooling, moisture management, and elasticity. For luxury knitwear, a different ratio might be used, such as 30% cooling fiber 300, 40% wool, and 30% Tencel, combining the cooling benefits with the warmth and softness of wool, and the smoothness of Tencel.



FIG. 4 illustrates an embodiment of fabric production. The yarn 400 produced through the yarn spinning 110 process may be a blend of cooling fibers 114 and other fibers 112. The integration of the cooling fibers 114 ensures that the yarn 400 offers dynamic thermal regulation, absorbing and releasing heat to maintain a comfortable temperature.


In some embodiments, different ratios of cooling fibers 114 and other fibers 112 in yarn 400 may be tailored to meet the specific needs of various textile applications. For activewear, a yarn 400 blend may consist of 50% cooling fiber 114, 40% Supima® cotton, and 10% additional performance fibers, which may ensure effective thermal regulation, softness, durability, and flexibility, making it ideal for high-performance sportswear. For everyday comfort clothing, a blend may include 20% cooling fiber 114, 60% organic cotton, and 20% linen, which may provide a soft, natural feel with subtle cooling effects, enhanced breathability, and slight stretch for added comfort. In performance sportswear, a yarn 400 might be composed of 60% cooling fiber 114, 40% Regen Cotton, providing a balance between cooling and moisture management. For luxury knitwear, a different ratio might be used, such as 30% cooling fiber 114, 40% wool, and 30% Tencel, combining the cooling benefits with the warmth and softness of wool, and the smoothness of Tencel.


The fabric production 404, may include transforming yarns 400 and other yarns 402 into finished fabric 406 ready for use in various applications, such as clothing, bedding, upholstery, and industrial textiles. The other yarns 402 may be recycled spandex, and or made of bio-synthetics fibers. In some embodiments, fabric production 104 may include knitting, weaving, dyeing, finishing, etc. In some embodiments, knitting may involve interloping yarns 400 and other yarn 402 to create a fabric 406 with a natural stretch. In some embodiments, knitting may include circular knitting, which is used for seamless garments, and flat knitting, which may be used for flat fabrics like sweater knits. In some embodiments, 3D knitting may be a specialized form of knitting, where complex shapes and structures may be created directly from the yarn 400.


In some embodiments, weaving may involve interlacing yarns 400 at right angles to form a fabric 406. The vertical yarns 400, known as the warp, are held under tension, while the horizontal yarns 400, known as the weft, are woven through them. In some embodiments, different weave patterns, such as plain weave, twill, or satin weave, may be used to create various textures and strengths in the fabric 406.


In some embodiments, fabric production 404 may include cut-and-sew knits in which knitted fabrics are produced in large sheets and are then cut into pieces and sewn together to create garments. In some embodiments, the fabric 406 may undergo pre-treatment processes such as scouring, bleaching, or mercerizing to prepare the fibers 114 for better dye absorption. In some embodiments, the yarn 400 may be immersed in a dye solution where it absorbs color. The dyeing process may be done using various methods, such as top dyeing, piece dyeing, yarn dyeing, or garment dyeing.


In some embodiments, the fabric 406 may undergo mechanical finishing processes such as calendaring, brushing, or shearing. In some embodiments, chemical treatments may be applied to impart specific properties to the fabric 406, such as water repellency, flame resistance, or antimicrobial activity. The finished fabric 406 may cool the skin, resist odor, increase blood circulation, and is soft, comfortable, and biodegradable and is an alternative to synthetic materials. The finished fabric 406 is created by blending a viscose solution, made from cotton scrap waste as the cellulose base, with microscopic jade stone and chitosan. This solution is spun into yarn 108, which is then combined with recycled spandex to produce a special blend of knitted fabrics, resulting in the finished fabric 406.



FIGS. 5A and 5B illustrate microscopic views of the original surface state of the base material 126 and the base material 126 surfaces coated with phase change materials.



FIG. 5A provides a microscopic view of the original surface state of the base material 126. The base material 126 may be a mesoporous material with high nanopore porosity, such as diatomaceous earth, sepiolite, zeolite, and kaolinite. In some embodiments, the base materials 126 may contain an extensive network of nanopores, which allows for the efficient encapsulation and stabilization of functional additives. In some embodiments, the high porosity of the base material 126 ensures that the embedded phase change materials 128 are well-distributed within the fiber 114, enabling uniform thermal regulation and enhanced mechanical stability.



FIG. 5B provides a microscopic view of the base material 126 surfaces coated with phase change materials. The embedded base material 124 may be composed of a nano-engineered structure designed to achieve functional cooling and antimicrobial benefits within the cooling fiber 114. In some embodiments, the core of the composition may be the mesoporous base material 126 characterized by its high nanopore porosity, which serves as the matrix for embedding phase change materials 128. In some embodiments, the phase change materials 128 may be distributed within the pores of the base material 126 in their solid or liquid state. The dispersion may be achieved through techniques such as impregnation or encapsulation to ensure that the phase change materials 128 are securely lodged within the mesoporous structure, allowing for controlled thermal exchanges with the surrounding environment as the cooling fiber 114 is subjected to temperature variations. In some embodiments, the phase change materials 128 may be dissolved into the base material's 126 pores using solvents or other suitable carriers. For example, upon drying or curing, the solvent evaporates, leaving the phase change material 128 embedded within the nanopores and ensuring intimate contact between the phase change material 128 and the base material 126, which optimizes the thermal conductivity and phase change efficiency of the cooling fiber 114.


The functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.

Claims
  • 1. A method for producing a cooling fiber with enhanced thermoregulation properties, the method comprising: embedding particles of phase change material into a mesoporous base material;blending the base material that has been embedded with the phase change material particles into a compound powder; andforming one or more strands of a cooling fiber from the compound powder, wherein the phase change material particles are distributed along the strands of the cooling fiber.
  • 2. The method of claim 1, further comprising mixing particles of a high specific heat material into the base material embedded with the phase material.
  • 3. The method of claim 2, wherein the high specific heat material includes one or more of jade, diatomaceous earth, sepiolite, talc, zeolite, kaolinite, monazite, mica, serpentine, basalt, and oxides of silicon, aluminum, magnesium, sodium, calcium, phosphide, nitride, and silicate.
  • 4. The method of claim 1, wherein forming the strands of the cooling fiber includes blending the compound powder with a cellulose source into a mixture.
  • 5. The method of claim 4, wherein forming the strands of the cooling fiber further includes dissolving the mixture in a viscose solution.
  • 6. The method of claim 5, wherein forming the strands of the cooling fiber further includes viscose spinning of the mixture using a spinning machine.
  • 7. The method of claim 6, wherein forming the strands of the cooling fiber further includes extruding the mixture through spinnerets into a coagulation bath.
  • 8. The method of claim 1, further comprising spinning the strands of the cooling fiber into a yarn, and adding one or more other fibers to the cooling fiber during spinning, wherein the other fibers are added in a predetermined proportion relative to the cooling fiber.
  • 9. The method of claim 1, further comprising adding one or more additional types of yarn into the yarn spun from the cooling fiber, and interlacing the yarn with the additional types of yarn to form a fabric structure.
  • 10. The method of claim 1, wherein the base material includes a network of nanopores, within which the phase change material is distributed.
  • 11. The method of claim 1, wherein the phase change material is distributed via impregnation dispersion technique.
  • 12. The method of claim 1, wherein the phase change material is distributed via encapsulation dispersion technique.
  • 13. The method of claim 1, wherein embedding the phase change material particles into the base material includes dissolving the phase change material particles into pores of the base material using solvents.
  • 14. The method of claim 1, further comprising micronizing the base material, wherein a particle size of the base material is reduced to nanometer range.
  • 15. The method of claim 14, wherein micronizing the base material includes high-energy milling.
  • 16. The method of claim 1, further comprising drying the base material and the phase material prior to blending.
  • 17. The method of claim 1, wherein blending the base material into the compound powder includes high shear mixing.
  • 18. A yarn spun from the cooling fiber produced in accordance with the method of claim 1.
  • 19. A fabric woven from the cooling fiber produced in accordance with the method of claim 1.
  • 20. An article made from a fabric that includes the cooling fiber produced in accordance with the method of claim 1.
CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the priority benefit of U.S. provisional patent application No. 63/594,188 filed on Oct. 30, 2023 and titled “Hyper-Cool Jade,” the full disclosure of which is incorporated by reference herein.

Provisional Applications (1)
Number Date Country
63594188 Oct 2023 US