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JP-2026514232-A - Thermoplastic copolyester elastomer yarn

JP2026514232AJP 2026514232 AJP2026514232 AJP 2026514232AJP-2026514232-A

Abstract

A thermoplastic copolyester elastomer yarn and a method for producing a thermoplastic copolyester elastomer yarn are disclosed. The yarn comprises a filament formed from a thermoplastic copolyester elastomer composition comprising a thermoplastic copolyester elastomer including hard segments and soft segments. The thermoplastic copolyester elastomer exhibits a flexural elasticity of about 300 MPa or less as measured according to ISO 178:2019 at a temperature of about 23°C and a melting temperature of about 100°C to about 230°C as measured according to ISO 11357-3:2018. The yarn has a linear density of about 1 to about 2000 denier per filament and exhibits an elongation at break of about 300% or more as measured according to ASTM D2653-07 (2018) at a temperature of about 23°C.

Inventors

  • コヴェリ，カーメン・エイ
  • オールダム，グレッグ・シー
  • ロンバルド，ジェームズ・エイ
  • クラッツ，カトリーナ

Assignees

  • セラニーズ・ポリマーズ・ホールディング，インコーポレーテッド

Dates

Publication Date
20260507
Application Date
20240426
Priority Date
20230428

Claims (20)

  1. A yarn comprising filaments formed from a thermoplastic copolyester elastomer composition containing a thermoplastic copolyester elastomer with hard segments and soft segments, wherein the thermoplastic copolyester elastomer exhibits a flexural modulus of about 300 MPa or less as measured according to ISO 178:2019 at a temperature of about 23°C and a melting temperature of about 100°C to about 230°C as measured according to ISO 11357-3:2018, and further, the yarn has a linear density of about 1 to about 2000 denier per filament and exhibits an elongation at break of about 300% or more as measured according to ASTM D2653-07 (2018) at a temperature of about 23°C.
  2. The yarn according to claim 1, exhibiting shrinkage of approximately 50% or less as measured according to ASTM D2259-02 (2016) (Section 6.6.1 - Dry heat exposure).
  3. The yarn according to claim 1 or 2, exhibiting a tenacity of approximately 0.7 grams or more per denier, as measured according to ASTM D2653-07 (2018) at a temperature of approximately 23°C.
  4. A yarn according to any one of claims 1 to 3, exhibiting at least about 75% recoverable elasticity as measured according to ASTM D6720-07 (2018).
  5. The yarn according to any one of claims 1 to 4, wherein the thermoplastic copolyester elastomer exhibits one or more Shore D hardnesses of about 60 or less, as measured according to ISO 868:2003 (test time of 15 seconds) at a temperature of about 23°C, or a tensile stress at fracture of about 45 MPa or less, as measured according to ISO 527-1/-2 (2012) at a temperature of about 23°C.
  6. The yarn according to any one of claims 1 to 5, wherein the thermoplastic copolyester elastomer is a thermoplastic copolyether ester elastomer.
  7. The yarn according to any one of claims 1 to 6, wherein the thermoplastic copolyester elastomer is a thermoplastic copolyester elastomer containing a hard segment and a soft segment, the hard segment constitutes about 20% to about 70% by weight of the thermoplastic copolyester elastomer, and the soft segment constitutes about 30% to about 80% by weight of the thermoplastic copolyester elastomer.
  8. The yarn according to any one of claims 1 to 7, wherein the thermoplastic elastomer is a thermoplastic copolyester elastomer containing a hard segment and a soft segment, and the hard segment is derived from at least one aromatic dicarboxylic acid and/or a diester thereof and at least one diol containing 2 to 15 carbon atoms.
  9. The yarn according to claim 8, wherein the aromatic dicarboxylic acid comprises terephthalic acid, isophthalic acid, or a combination thereof, and the diol comprises ethylene glycol, 1,4-butanediol, 1,3-propanediol, or a combination thereof.
  10. The yarn according to any one of claims 1 to 9, wherein the thermoplastic elastomer is a thermoplastic copolyester elastomer containing a hard segment and a soft segment, and the soft segment is derived from at least one aromatic dicarboxylic acid and/or a diester thereof and at least one poly(alkylene oxide) glycol.
  11. The yarn according to claim 10, wherein the aromatic dicarboxylic acid comprises terephthalic acid, isophthalic acid, or a combination thereof, and the poly(alkylene oxide) glycol comprises poly(tetramethylene oxide) glycol, poly(trimethylene oxide) glycol, poly(propylene oxide) glycol, poly(ethylene oxide) glycol, poly(hexamethylene oxide) glycol, or a combination thereof.
  12. The yarn according to any one of claims 1 to 11, wherein the thermoplastic copolyester elastomer comprises a thermoplastic copolyether ester elastomer prepared from monomers containing (1) poly(tetramethylene oxide) glycol, (2) a dicarboxylic acid selected from isophthalic acid, terephthalic acid, or a mixture thereof, and (3) a diol selected from 1,4-butanediol, 1,3-propanediol, or a mixture thereof.
  13. The yarn according to any one of claims 1 to 12, wherein the filament is coated with a finishing agent, and the finishing agent coats at least about 50% of the surface area of the filament.
  14. The yarn according to any one of claims 1 to 13, wherein the filament is coated with a finishing agent containing a finishing oil containing silicone oil.
  15. A monofilament yarn, as described in any one of claims 1 to 14.
  16. The yarn according to claim 15, comprising an axial core in which three or more lobes are arranged radially around the axial core.
  17. A multifilament yarn, as described in any one of claims 1 to 14.
  18. The yarn according to claim 17, wherein the multifilament yarn includes a first filament at least partially adhered to a second filament, and the first filament and the second filament are each formed from the thermoplastic copolyester elastomer composition.
  19. The yarn according to claim 17 or 18, wherein the multifilament yarn further comprises a third filament, the third filament being at least partially bonded to the first filament, the second filament, or both.
  20. A method for manufacturing yarn according to any one of claims 1 to 19, wherein the method is Extruding a molten material containing the thermoplastic copolyester elastomer composition through a spinneret; Pulling the filament from the spinneret to the supply roller; Rapid cooling of the filament using air; Applying a finishing agent to the aforementioned filament; A method comprising collecting the filament on a winding roller.

Description

Cross-reference of related applications This application claims the benefit of filing U.S. Provisional Patent Application No. 63/498,866, filed on 28 April 2023, which is incorporated herein by reference in its entirety. Non-stretchable yarns, such as polyester and nylon, are commonly used to manufacture articles such as fabrics and furniture. The filaments used to produce such yarns can be spun with minimal filament breakage, and corresponding breakage can also be minimized during fabric processing. Another class of materials, namely thermoplastic copolyester elastomers, have recently been used for a variety of applications due to their ability to function as thermoplastics, particularly their ability to reform when heated, while also exhibiting specific properties typical of elastomers. As a result, these materials can also be used as elastomeric stretchable yarns for forming various articles. However, these yarns may have a higher-than-desirable tendency to break during spinning and/or further processing. In addition, when using multifilament yarns made from such thermoplastic copolyester elastomers, individual filaments may separate from the yarn bundle during unwinding and/or further processing, thereby compromising the integrity of the yarn and the resulting article. This is a schematic process diagram of an apparatus useful for manufacturing filaments according to one embodiment of the present disclosure.This is a cross-sectional view of a filament having a two-lobe cross-section according to one embodiment of the present disclosure.This is a cross-sectional view of a filament having a two-lobe cross-section according to one embodiment of the present disclosure.This is a cross-sectional view of a two-filament multifilament according to another embodiment of the present disclosure.This is a cross-sectional view of a monofilament having a three-lobe cross-section according to another embodiment of the present disclosure.This is a cross-sectional view of a monofilament having a three-lobe cross-section according to another embodiment of the present disclosure.This is a cross-sectional view of a monofilament having a three-lobe cross-section according to another embodiment of the present disclosure.This is a cross-sectional view of a monofilament having a four-lobe cross-section according to another embodiment of the present disclosure.This is a cross-sectional view of a monofilament having a four-lobe cross-section according to another embodiment of the present disclosure.This is a cross-sectional view of a monofilament having a four-lobe cross-section according to another embodiment of the present disclosure.This is a cross-sectional view of a three-filament multifilament according to another embodiment of the present disclosure.This is a cross-sectional view of a four-filament multifilament according to another embodiment of the present disclosure.The knit structure according to the embodiment of this disclosure is shown.An optical microscope image of the three-lobe monofilament yarn of Example 1 is provided.An optical microscope image of the multifilament yarn of Example 2 is provided. The repeated use of reference letters in this specification and drawings is intended to represent the same or similar features or elements of the present invention. Those skilled in the art will understand that this discussion is merely a description of exemplary embodiments and is not intended to limit broader aspects of the disclosure. Generally speaking, this disclosure relates to thermoplastic copolyester elastomer yarns. The inventors have discovered that by utilizing thermoplastic copolyester elastomers such as those disclosed herein, filaments and resulting yarns with desired properties for various applications, particularly textile applications, can be obtained. In particular, articles obtained by utilizing thermoplastic copolyester elastomer yarns such as those disclosed herein may be lighter, dry faster, and/or more breathable than those made from other materials. In addition, because thermoplastic copolyester elastomers can be reformed by heating, like thermoplastic plastics, yarns formed from thermoplastic copolyester elastomers and the resulting articles may contribute to a recyclable and circular ecosystem. For example, these materials may be reused and reformed, and therefore, unlike other types of materials typically used, may not necessarily need to be disposed of. Furthermore, the properties of thermoplastic copolyester elastomers and the resulting filaments and yarns enable the use of these materials to overcome certain previous problems. For example, yarns with elongation exceeding 300% can be spun relatively quickly to form the resulting articles while minimizing filament and yarn breakage. In addition, yarns can also result in fewer defects during knitting applications (e.g., drop stitches, holes, poor selvage, broken filaments, yarn breakage, inconsistent yarn denier in the fabric, etc.). In this