Hemp-based char or oils and polymers formed as fibers or films having enhanced properties

Abstract

A process of forming a fiber comprised of a plurality of bio-char particles, comprising: combining a portion of a polymer with a hemp derivative, said hemp derivative selected form a hemp carbon made by pyrolyzing a quantity of hemp stalk at between 1100-1500° C. to create a char; adding the char to a milling vessel and milling the char for a period of between 1 to 16 hours, and a full spectrum hemp extract, or combinations thereof, wherein the polymer and hemp derivative are extruded to form a fiber.

What is claimed is: 
     
         1 . A method of manufacturing a nonmetallic conductive fiber comprising:
 carbonizing a portion of hemp in a furnace, said furnace being flushed with nitrogen and then heated to at least 1100° C., wherein the at least 1100° C. temperature is held for at least 60 minutes and wherein nitrogen flow is maintained over the heating and hold times to maintain a low oxygen environment;   removing the hemp from the furnace and cooling it to room temperature;   milling the cooled hemp to an average particle size of less than 2 microns; and   combining the milled hemp with a polymer and postprocessing the hemp and polymer into a fiber;   wherein the fiber comprises between 0.1 and 20 weight percent of the milled hemp.   
     
     
         2 . The method of  claim 1  wherein said fiber is a single component yarn, a bicomponent yarn, or a tricomponent yarn. 
     
     
         3 . The method of  claim 1  wherein the fiber is a thread having a denier size of between 0.1 and 40. 
     
     
         4 . The method of  claim 1  wherein the polymer is selected from the group consisting of: a thermoset polymer, a thermoplastic polymer, and combinations thereof. 
     
     
         5 . The method of  claim 1  further comprising a full spectrum hemp extract wherein said full spectrum hemp extract comprises between 0.1 and 2.0 weight percent of the fiber. 
     
     
         6 . The method of  claim 1  wherein the polymer and portion of hemp derivative are further mixed with at least one excipient selected from the group consisting of: pigments, UV stabilizers, antioxidants, heat stabilizing components, flame retardants, antimicrobial agents, nucleating or clarifying agents, optical brighteners, compatibilizers, and combinations thereof. 
     
     
         7 . The method of  claim 1  wherein the milled hemp comprises 95% of particles between 0.1 and 2 microns. 
     
     
         8 . The method of  claim 1  wherein the portion of milled hemp is admixed via a master batch, said master batch comprising between 1% and 50% of the total weight of the fiber. 
     
     
         9 . The method of  claim 1  wherein the temperature is increased at a linear heat ramp. 
     
     
         10 . The method of  claim 1  wherein at least 90% of the particles are less than 2 microns. 
     
     
         11 . The method of  claim 1  further comprising the addition of 0.1-20 weight percent of an essential oil. 
     
     
         12 . The method of  claim 11  wherein the essential oil is selected from the group consisting of: a hemp-based oil, allspice, angelica, anise, basil, bay leaf, benzoin, bergamot, birch, bitter almond, black pepper, boldo, buchu, cajuput, calamus, chamomile, camphor, caraway, cardamom, carrot seed, cassia, catnip, cedarwood, cinnamon, citronella, clary sage, clove, coriander, cumin, cypress, davana, dill, elemi, eucalyptus, fennel, frankincense, galbanum, geranium, ginger, grapefruit, helichrysum, hyssop, jasmine, juniper, lavandin, lavender, lemon, lemongrass, lime, mandarin, manuka, marjoram, melissa, mugwort, mullein, mustard, myrrh, myrtle, neroli, niaouli, nutmeg, oakmoss, orange, oregano, palma rosa, parsley, patchouli, pennyroyal, peppermint, petitgrain, pimento, pine, ravensara, rose, rosemary, rosewood, rue, sage, sandalwood, spearmint, spikenard, tagetes, tangerine, tansy, tarragon, tea tree, thuja, thyme, tuberose, vanilla, vetiver, wintergreen, wormwood, yarrow, ylang ylang, and combinations thereof. 
     
     
         13 . The method of  claim 1  wherein the milled hemp comprises between 0.01% and 20% of a master batch, and wherein the milled hemp comprises between 0.01% and 5% of the total weight of an extruded fiber. 
     
     
         14 . A nonmetallic conductive fiber comprising:
 a polymer and a carbonized hemp having an average particle size of less than 2 microns;   wherein said carbonized hemp comprises between 0.1 and 20 weight percentage of said fiber, and wherein said carbonized hemp is made by being heated to at least 1100° C., wherein the at least 1100° C. temperature is held for at least 60 minutes and wherein nitrogen flow is maintained over the heating and hold times to maintain a low oxygen environment and then milled to an average particle size of less than 2 microns.   
     
     
         15 . The fiber of  claim 14  wherein at least 90% of the particles are less than 2 microns. 
     
     
         16 . The fiber of  claim 14  further comprising the addition of 0.1-20 weight percent of an essential oil. 
     
     
         17 . The fiber of  claim 14  further comprising a full spectrum hemp extract wherein said full spectrum hemp extract comprises between 0.1 and 2.0 weight percent of the fiber. 
     
     
         18 . The fiber of  claim 14  further comprising at least one excipient selected from the group consisting of: pigments, UV stabilizers, antioxidants, heat stabilizing components, flame retardants, antimicrobial agents, nucleating or clarifying agents, optical brighteners, compatibilizers, and combinations thereof. 
     
     
         19 . The fiber of  claim 14  wherein said fiber is a single component yarn, a bicomponent yarn, or a tricomponent yarn. 
     
     
         20 . The fiber of  claim 14  wherein the polymer is selected from the group consisting of: a thermoset polymer, a thermoplastic polymer, and combinations thereof.