Stable Suspensions Containing Microcapsules and Methods for Preparation Thereof

Abstract

A stable suspension for the production of a temperature-regulating, polymer-containing material or fabric, comprises a solvent and a plurality of microcapsules containing at least one phase-change material. The microcapsules are incorporated in the polymer-containing material, and the stable suspension is characterized in that the solvent is capable of dissolving a fabric-forming component selected from the group consisting of at least one of the polymer and precursors thereof and the suspension is stable for at least about 20 hours. A method for manufacturing a suspension comprising a solvent and a plurality of microcapsules containing at least one phase-change material comprises providing microcapsules containing a phase-change material, providing a solvent capable of dissolving a fabric-forming component selected from the group consisting of at least one of the polymer and precursors thereof, and mixing the solvent and the microcapsules to form the suspension.

1 - 39 . (canceled) 
   
   
       40 . A stable suspension for the production of a temperature-regulating, polymer-containing material, the suspension comprising a solvent and a plurality of microcapsules containing at least one phase-change material, wherein the microcapsules are to be incorporated in the polymer-containing material, and wherein the stable suspension is characterized in that:
 (i) the solvent is capable of dissolving a fabric-forming component selected from the group consisting of at least one of the polymer and precursors thereof; and   (ii) the suspension is stable for at least about 20 hours.   
   
   
       41 . The suspension of  claim 40 , further characterized in that at least about 95% of the microcapsules stay intact in the suspension for at least about 20 hours. 
   
   
       42 . The suspension of  claim 40 , wherein the material is formed from at least one type of polymeric fiber. 
   
   
       43 . The suspension of  claim 40 , wherein the polymer is selected from the group consisting of acrylonitrile-based polymers, cellulose-based polymers, polyester-based polymers, polyamide-based polymers and polyolefin based polymers. 
   
   
       44 . The suspension of  claim 40 , wherein the solvent is an aqueous solution. 
   
   
       45 . The suspension of  claim 40 , further comprising at least one further component selected from the group consisting of a defoaming agent, a flow-control agent, a wetting agent, a dispersing agent and surfactant. 
   
   
       46 . The suspension of  claim 44 , wherein the aqueous solutions comprise at least one further component selected from the group consisting of sodium bases, sodium thiocyanate, zinc chloride, n-methyl morpholine oxide, ammonia, copper sulfate, nitric acid, acetone, DMF and NMP. 
   
   
       47 . The suspension of  claim 40 , wherein the microcapsules comprise a shell and a core and wherein the shell is formed from at least one component selected from the group consisting of acrylic acid and derivatives thereof, methacrylic acid and derivatives thereof, formaldehyde, isocyanate, urea, carboxylic acid derivatives, silica precursor and gelatin. 
   
   
       48 . The suspension of  claim 40 , wherein the microcapsules comprise a shell and a core and wherein the core comprises a phase-change material selected from the group consisting of octadecane, straight-chain hydrocarbons with 15 to 25 carbon atoms, and branched-chain hydrocarbons with 15 to 25 carbon atoms. 
   
   
       49 . The suspension of  claim 40 , wherein the microcapsules comprise a shell and a core and the weight ratio between the shell and core is in the range between about 0.5:9.5 and about 4:6. 
   
   
       50 . The suspension of  claim 40 , wherein the microcapsules form between about 5 and about 40 percent by weight of the suspension. 
   
   
       51 . The suspension of  claim 40 , wherein the microcapsules have a maximum linear dimension ranging between about 0.1 and about 20 micron. 
   
   
       52 . The suspension of  claim 40 , further comprising at least one compound with functionality, the functionality being selected from the group consisting of fire retardation, bioactivity, antimicrobial activity, odor resistance, UV absorption, moisture management and resistance to water, grease, dirt and/or stain. 
   
   
       53 . The suspension of  claim 40 , wherein the polymer is acrylonitrile-based, wherein the solvent comprises water and sodium thiocyanate, wherein the concentration of the sodium thiocyanate ranges between about 40 and about 60 percent by weight of the solvent and wherein the microcapsules form between about 5 and about 30 percent by weight of the suspension. 
   
   
       54 . The suspension of  claim 40 , wherein the polymer is cellulose-based, wherein the solvent comprises water and sodium hydroxide, wherein the concentration of the sodium hydroxide ranges between about 1 percent and about 5 percent and wherein the microcapsules form between about 5 and about 30 percent of the suspension. 
   
   
       55 . The suspension of  claim 40 , further comprising at least one fabric-forming component selected from the group consisting of a polymer and a precursor thereof. 
   
   
       56 . A method for manufacturing a suspension comprising a solvent and a plurality of microcapsules containing at least one phase-change material, the method comprising:
 providing microcapsules containing a phase-change material;   providing a solvent capable of dissolving a fabric-forming component selected from the group consisting of at least one of the polymer and precursors thereof; and   mixing the solvent and the microcapsules to form the suspension.   
   
   
       57 . The method of  claim 56  further comprising adding at least one further component selected from the group consisting of a defoaming agent, a flow-control agent, a wetting agent, a dispersing agent and a surfactant. 
   
   
       58 . The method of  claim 56 , wherein the microcapsules are provided as a separate suspension of microcapsules in a fluid. 
   
   
       59 . The method of  claim 58 , wherein the suspension of microcapsules in a fluid is provided in a vessel and the solvent is added to the microcapsules in the vessel to form the first suspension. 
   
   
       60 . The method of  claim 58 , wherein the viscosity of the suspension of microcapsules in a fluid is in the range of between about 100 and about 3000 cps. 
   
   
       61 . The method of  claim 56 , further comprising wet spinning or dry spinning the suspension. 
   
   
       62 . The method of  claim 61 , wherein the suspension is spun to form fibers. 
   
   
       63 . The method of  claim 62 , wherein the fibers are combined with other fibers to form a fabric.