Monofilament Fibers Comprising at Least One Filler, and Processes for Their Production

Abstract

Disclosed herein are monofilament fibers comprising at least one polymeric resin and at least one coated filler, wherein the at least one coated filler has an average particle size of less than or equal to about 3 microns and/or has a top cut of less than or equal to about 10 microns, and wherein the at least one coated filler is present in an amount of less than or equal to about 50% by weight, relative to the total weight of the monofilament fibers. Also disclosed herein are methods for producing monofilament fibers comprising adding ground calcium carbonate to at least one polymeric resin and extruding the resulting mixture.

1 - 32 . (canceled) 
     
     
         33 . A monofilament fiber comprising at least one polymeric resin and at least one coated filler having a top cut of less than about 10 microns, wherein the at least one coated filler comprises at least one ground calcium carbonate and at least one coating, and wherein the at least one coated filler is present in the fiber in an amount less than about 50 wt %, relative to the total weight of the monofilament fiber. 
     
     
         34 . The monofilament fiber of  claim 33 , wherein the at least one ground calcium carbonate is present in an amount less than about 25 wt %, relative to the total weight of the monofilament fiber. 
     
     
         35 - 36 . (canceled) 
     
     
         37 . The monofilament fiber if  claim 33 , wherein the at least one coating is at least one organic material chosen from fatty acids and salts and esters thereof. 
     
     
         38 . The monofilament fiber of  claim 37 , wherein the at least one organic material is chosen from stearic acid, stearate, ammonium stearate, and calcium stearate. 
     
     
         39 . The monofilament fiber of  claim 33 , wherein the at least one polymeric resin is at least one thermoplastic polymer. 
     
     
         40 . The monofilament fiber of  claim 39 , wherein the at least one thermoplastic polymer is chosen form the group consisting of polyolefins, polyamides, polyester, copolymers thereof, and blends thereof. 
     
     
         41 . The monofilament fiber of  claim 40 , wherein the polyolefins are chosen from polypropylene and polyethylene homopolymers and copolymers. 
     
     
         42 . The monofilament fiber of  claim 40 , wherein the polyamide is nylon. 
     
     
         43 . (canceled) 
     
     
         44 . The monofilament fiber of  claim 33 , further comprising at least one additive chosen from additional mineral filler,s inorganic compounds, waxes, optical brighteners, heat stabilizers, antioxidants, anti-static agents, anti-blocking agents, dyestuffs, pigments, luster improving agents, surfactants, natural oils, and synthetic oils. 
     
     
         45 . The monofilament fiber of  claim 33 , wherein the at least one ground calcium carbonate has a top cut of less than about 10 microns. 
     
     
         46 - 48 . (canceled) 
     
     
         49 . The monofilament fiber of  claim 33 , wherein the at least one ground calcium carbonate has a top cut ranging from about 4 microns to about 10 microns. 
     
     
         50 - 51 . (canceled) 
     
     
         52 . The monofilament fiber of  claim 33 , wherein the at least one ground calcium carbonate has an average particle size of less than or equal to about 3 microns. 
     
     
         53 - 54 . (canceled) 
     
     
         55 . The monofilament fiber of  claim 33 , wherein the at least one ground calcium carbonate has an average particle size ranging from about 1 micron to about 3 microns. 
     
     
         56 - 58 . (canceled) 
     
     
         59 . A process for producing monofilament fibers comprising:
 (a) mixing at least one polymeric resin with at least one coated ground calcium carbonate having an average particle size of less than or equal to about 3 microns;   (b) heating the mixture at least to the softening point of the at least one polymeric resin; and   (c) extruding the mixture to form monofilament fibers;   wherein the at least one coated ground calcium carbonate is present in the monofilament fibers in an amount less than about 50 wt %, relative to the total weight of the monofilament fibers.   
     
     
         60 . (canceled) 
     
     
         61 . (canceled) 
     
     
         62 . A process for producing monofilament fibers comprising:
 (a) producing a masterbatch, comprising mixing and then extruding at least one first polymeric resin with at least one coated ground calcium carbonate having an average particle size of less than or equal to about 3 microns.   (b) mixing the masterbatch with at least one second polymeric resin, to form a resulting mixture, and   (c) extruding the resulting mixture to form monofilament fibers;   wherein the at least one coated ground calcium carbonate is present in the monofilaments fibers in an amount less than about 50 wt %, relative to the total weight of the fibers.   
     
     
         63 . The process of  claim 62 , wherein the masterbatch is pelletized before mixing with the at least one second polymeric resin. 
     
     
         64 . The process of  claim 62 , wherein the at least one coated ground calcium carbonate is present in the masterbatch in an amount ranging from about 20 to about 75 wt %, relative to the total weight of the masterbatch. 
     
     
         65 . The process of  claim 62 , further comprising attenuating the fibers by high-speed drawing. 
     
     
         66 - 82 . (canceled) 
     
     
         83 . The monofilament fiber of  claim 33 , wherein the monofilament fiber has a size ranging from about 0.1 to about 120 denier. 
     
     
         84 . (canceled) 
     
     
         85 . The process of  claim 59 , wherein the monofilament fibers have sizes ranging from about 0.1 to about 120 denier. 
     
     
         86 - 92 . (canceled)