US20220411970A1 - Bicomponent thermoplastic polyurethane fibers and fabrics made therefrom - Google Patents
Bicomponent thermoplastic polyurethane fibers and fabrics made therefrom Download PDFInfo
- Publication number
- US20220411970A1 US20220411970A1 US17/623,955 US202017623955A US2022411970A1 US 20220411970 A1 US20220411970 A1 US 20220411970A1 US 202017623955 A US202017623955 A US 202017623955A US 2022411970 A1 US2022411970 A1 US 2022411970A1
- Authority
- US
- United States
- Prior art keywords
- thermoplastic polyurethane
- fabric
- bicomponent fiber
- core
- astm
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000004433 Thermoplastic polyurethane Substances 0.000 title claims abstract description 91
- 239000000835 fiber Substances 0.000 title claims abstract description 78
- 229920002803 thermoplastic polyurethane Polymers 0.000 title claims description 90
- 239000004744 fabric Substances 0.000 title claims description 38
- 229920000728 polyester Polymers 0.000 claims abstract description 33
- 239000000203 mixture Substances 0.000 claims description 24
- 238000002844 melting Methods 0.000 claims description 21
- 230000008018 melting Effects 0.000 claims description 21
- 239000004970 Chain extender Substances 0.000 claims description 16
- 239000007795 chemical reaction product Substances 0.000 claims description 12
- PTIXVVCRANICNC-UHFFFAOYSA-N butane-1,1-diol;hexanedioic acid Chemical compound CCCC(O)O.OC(=O)CCCCC(O)=O PTIXVVCRANICNC-UHFFFAOYSA-N 0.000 claims description 7
- OPZZWWFHZYZBRU-UHFFFAOYSA-N butanedioic acid;butane-1,1-diol Chemical compound CCCC(O)O.OC(=O)CCC(O)=O OPZZWWFHZYZBRU-UHFFFAOYSA-N 0.000 claims description 7
- 238000004132 cross linking Methods 0.000 claims description 4
- 239000004745 nonwoven fabric Substances 0.000 claims 1
- 239000002759 woven fabric Substances 0.000 claims 1
- 239000005056 polyisocyanate Substances 0.000 description 14
- 229920001228 polyisocyanate Polymers 0.000 description 14
- 239000000543 intermediate Substances 0.000 description 12
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 10
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 9
- 229920001730 Moisture cure polyurethane Polymers 0.000 description 8
- 238000000034 method Methods 0.000 description 8
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 6
- 125000005442 diisocyanate group Chemical group 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 5
- 125000004432 carbon atom Chemical group C* 0.000 description 5
- 239000003054 catalyst Substances 0.000 description 5
- 150000001991 dicarboxylic acids Chemical class 0.000 description 5
- 238000009987 spinning Methods 0.000 description 5
- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
- 125000001931 aliphatic group Chemical group 0.000 description 4
- 239000003431 cross linking reagent Substances 0.000 description 4
- 150000002334 glycols Chemical class 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- DNIAPMSPPWPWGF-UHFFFAOYSA-N monopropylene glycol Natural products CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- YIMQCDZDWXUDCA-UHFFFAOYSA-N [4-(hydroxymethyl)cyclohexyl]methanol Chemical compound OCC1CCC(CO)CC1 YIMQCDZDWXUDCA-UHFFFAOYSA-N 0.000 description 3
- 125000003118 aryl group Chemical group 0.000 description 3
- 150000002009 diols Chemical class 0.000 description 3
- XXMIOPMDWAUFGU-UHFFFAOYSA-N hexane-1,6-diol Chemical compound OCCCCCCO XXMIOPMDWAUFGU-UHFFFAOYSA-N 0.000 description 3
- 238000002074 melt spinning Methods 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 239000000049 pigment Substances 0.000 description 3
- RTTZISZSHSCFRH-UHFFFAOYSA-N 1,3-bis(isocyanatomethyl)benzene Chemical compound O=C=NCC1=CC=CC(CN=C=O)=C1 RTTZISZSHSCFRH-UHFFFAOYSA-N 0.000 description 2
- 239000005059 1,4-Cyclohexyldiisocyanate Substances 0.000 description 2
- ICLCCFKUSALICQ-UHFFFAOYSA-N 1-isocyanato-4-(4-isocyanato-3-methylphenyl)-2-methylbenzene Chemical compound C1=C(N=C=O)C(C)=CC(C=2C=C(C)C(N=C=O)=CC=2)=C1 ICLCCFKUSALICQ-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- ALQSHHUCVQOPAS-UHFFFAOYSA-N Pentane-1,5-diol Chemical compound OCCCCCO ALQSHHUCVQOPAS-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 239000006096 absorbing agent Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 150000008064 anhydrides Chemical class 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 229910052797 bismuth Inorganic materials 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- -1 cycloaliphatic Chemical group 0.000 description 2
- NAQMVNRVTILPCV-UHFFFAOYSA-N hexane-1,6-diamine Chemical compound NCCCCCCN NAQMVNRVTILPCV-UHFFFAOYSA-N 0.000 description 2
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 2
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- AYLRODJJLADBOB-QMMMGPOBSA-N methyl (2s)-2,6-diisocyanatohexanoate Chemical compound COC(=O)[C@@H](N=C=O)CCCCN=C=O AYLRODJJLADBOB-QMMMGPOBSA-N 0.000 description 2
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 2
- 229920001610 polycaprolactone Polymers 0.000 description 2
- 239000004632 polycaprolactone Substances 0.000 description 2
- 229920005906 polyester polyol Polymers 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 235000013772 propylene glycol Nutrition 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 description 2
- DNIAPMSPPWPWGF-VKHMYHEASA-N (+)-propylene glycol Chemical compound C[C@H](O)CO DNIAPMSPPWPWGF-VKHMYHEASA-N 0.000 description 1
- HJIAMFHSAAEUKR-UHFFFAOYSA-N (2-hydroxyphenyl)-phenylmethanone Chemical class OC1=CC=CC=C1C(=O)C1=CC=CC=C1 HJIAMFHSAAEUKR-UHFFFAOYSA-N 0.000 description 1
- KMOUUZVZFBCRAM-OLQVQODUSA-N (3as,7ar)-3a,4,7,7a-tetrahydro-2-benzofuran-1,3-dione Chemical compound C1C=CC[C@@H]2C(=O)OC(=O)[C@@H]21 KMOUUZVZFBCRAM-OLQVQODUSA-N 0.000 description 1
- DNIAPMSPPWPWGF-GSVOUGTGSA-N (R)-(-)-Propylene glycol Chemical compound C[C@@H](O)CO DNIAPMSPPWPWGF-GSVOUGTGSA-N 0.000 description 1
- YPFDHNVEDLHUCE-UHFFFAOYSA-N 1,3-propanediol Substances OCCCO YPFDHNVEDLHUCE-UHFFFAOYSA-N 0.000 description 1
- ALQLPWJFHRMHIU-UHFFFAOYSA-N 1,4-diisocyanatobenzene Chemical compound O=C=NC1=CC=C(N=C=O)C=C1 ALQLPWJFHRMHIU-UHFFFAOYSA-N 0.000 description 1
- OVBFMUAFNIIQAL-UHFFFAOYSA-N 1,4-diisocyanatobutane Chemical compound O=C=NCCCCN=C=O OVBFMUAFNIIQAL-UHFFFAOYSA-N 0.000 description 1
- SBJCUZQNHOLYMD-UHFFFAOYSA-N 1,5-Naphthalene diisocyanate Chemical compound C1=CC=C2C(N=C=O)=CC=CC2=C1N=C=O SBJCUZQNHOLYMD-UHFFFAOYSA-N 0.000 description 1
- 229940008841 1,6-hexamethylene diisocyanate Drugs 0.000 description 1
- YZGMIRBFYCQNRH-UHFFFAOYSA-N 2-(2-hydroxyethyl)benzene-1,3-diol Chemical compound OCCC1=C(O)C=CC=C1O YZGMIRBFYCQNRH-UHFFFAOYSA-N 0.000 description 1
- SXFJDZNJHVPHPH-UHFFFAOYSA-N 3-methylpentane-1,5-diol Chemical compound OCCC(C)CCO SXFJDZNJHVPHPH-UHFFFAOYSA-N 0.000 description 1
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 description 1
- JRQLZCFSWYQHPI-UHFFFAOYSA-N 4,5-dichloro-2-cyclohexyl-1,2-thiazol-3-one Chemical compound O=C1C(Cl)=C(Cl)SN1C1CCCCC1 JRQLZCFSWYQHPI-UHFFFAOYSA-N 0.000 description 1
- UUAGPGQUHZVJBQ-UHFFFAOYSA-N Bisphenol A bis(2-hydroxyethyl)ether Chemical compound C=1C=C(OCCO)C=CC=1C(C)(C)C1=CC=C(OCCO)C=C1 UUAGPGQUHZVJBQ-UHFFFAOYSA-N 0.000 description 1
- 102100024482 Cell division cycle-associated protein 4 Human genes 0.000 description 1
- PIICEJLVQHRZGT-UHFFFAOYSA-N Ethylenediamine Chemical compound NCCN PIICEJLVQHRZGT-UHFFFAOYSA-N 0.000 description 1
- 239000005057 Hexamethylene diisocyanate Substances 0.000 description 1
- 101100383112 Homo sapiens CDCA4 gene Proteins 0.000 description 1
- 239000005909 Kieselgur Substances 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- LGRFSURHDFAFJT-UHFFFAOYSA-N Phthalic anhydride Natural products C1=CC=C2C(=O)OC(=O)C2=C1 LGRFSURHDFAFJT-UHFFFAOYSA-N 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 101710194411 Triosephosphate isomerase 1 Proteins 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- UKLDJPRMSDWDSL-UHFFFAOYSA-L [dibutyl(dodecanoyloxy)stannyl] dodecanoate Chemical compound CCCCCCCCCCCC(=O)O[Sn](CCCC)(CCCC)OC(=O)CCCCCCCCCCC UKLDJPRMSDWDSL-UHFFFAOYSA-L 0.000 description 1
- NBJODVYWAQLZOC-UHFFFAOYSA-L [dibutyl(octanoyloxy)stannyl] octanoate Chemical compound CCCCCCCC(=O)O[Sn](CCCC)(CCCC)OC(=O)CCCCCCC NBJODVYWAQLZOC-UHFFFAOYSA-L 0.000 description 1
- 150000005215 alkyl ethers Chemical class 0.000 description 1
- 125000000217 alkyl group Chemical group 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 238000003556 assay Methods 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 150000001565 benzotriazoles Chemical class 0.000 description 1
- 230000001588 bifunctional effect Effects 0.000 description 1
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 1
- UQOQXWZPXFPRBR-UHFFFAOYSA-K bismuth dodecanoate Chemical compound [Bi+3].CCCCCCCCCCCC([O-])=O.CCCCCCCCCCCC([O-])=O.CCCCCCCCCCCC([O-])=O UQOQXWZPXFPRBR-UHFFFAOYSA-K 0.000 description 1
- QVYARBLCAHCSFJ-UHFFFAOYSA-N butane-1,1-diamine Chemical compound CCCC(N)N QVYARBLCAHCSFJ-UHFFFAOYSA-N 0.000 description 1
- JHIWVOJDXOSYLW-UHFFFAOYSA-N butyl 2,2-difluorocyclopropane-1-carboxylate Chemical compound CCCCOC(=O)C1CC1(F)F JHIWVOJDXOSYLW-UHFFFAOYSA-N 0.000 description 1
- 239000001030 cadmium pigment Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical class [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 229910000423 chromium oxide Inorganic materials 0.000 description 1
- 239000001031 chromium pigment Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- QYQADNCHXSEGJT-UHFFFAOYSA-N cyclohexane-1,1-dicarboxylate;hydron Chemical compound OC(=O)C1(C(O)=O)CCCCC1 QYQADNCHXSEGJT-UHFFFAOYSA-N 0.000 description 1
- FOTKYAAJKYLFFN-UHFFFAOYSA-N decane-1,10-diol Chemical compound OCCCCCCCCCCO FOTKYAAJKYLFFN-UHFFFAOYSA-N 0.000 description 1
- 150000004985 diamines Chemical class 0.000 description 1
- 239000012975 dibutyltin dilaurate Substances 0.000 description 1
- KORSJDCBLAPZEQ-UHFFFAOYSA-N dicyclohexylmethane-4,4'-diisocyanate Chemical compound C1CC(N=C=O)CCC1CC1CCC(N=C=O)CC1 KORSJDCBLAPZEQ-UHFFFAOYSA-N 0.000 description 1
- SZXQTJUDPRGNJN-UHFFFAOYSA-N dipropylene glycol Chemical compound OCCCOCCCO SZXQTJUDPRGNJN-UHFFFAOYSA-N 0.000 description 1
- GTZOYNFRVVHLDZ-UHFFFAOYSA-N dodecane-1,1-diol Chemical compound CCCCCCCCCCCC(O)O GTZOYNFRVVHLDZ-UHFFFAOYSA-N 0.000 description 1
- GHLKSLMMWAKNBM-UHFFFAOYSA-N dodecane-1,12-diol Chemical compound OCCCCCCCCCCCCO GHLKSLMMWAKNBM-UHFFFAOYSA-N 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000005886 esterification reaction Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N ferric oxide Chemical compound O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- MHIBEGOZTWERHF-UHFFFAOYSA-N heptane-1,1-diol Chemical compound CCCCCCC(O)O MHIBEGOZTWERHF-UHFFFAOYSA-N 0.000 description 1
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000003999 initiator Substances 0.000 description 1
- YOBAEOGBNPPUQV-UHFFFAOYSA-N iron;trihydrate Chemical compound O.O.O.[Fe].[Fe] YOBAEOGBNPPUQV-UHFFFAOYSA-N 0.000 description 1
- NIMLQBUJDJZYEJ-UHFFFAOYSA-N isophorone diisocyanate Chemical compound CC1(C)CC(N=C=O)CC(C)(CN=C=O)C1 NIMLQBUJDJZYEJ-UHFFFAOYSA-N 0.000 description 1
- 238000009940 knitting Methods 0.000 description 1
- 150000002596 lactones Chemical class 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 239000012764 mineral filler Substances 0.000 description 1
- 229910003455 mixed metal oxide Inorganic materials 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 229940117969 neopentyl glycol Drugs 0.000 description 1
- FVXBCDWMKCEPCL-UHFFFAOYSA-N nonane-1,1-diol Chemical compound CCCCCCCCC(O)O FVXBCDWMKCEPCL-UHFFFAOYSA-N 0.000 description 1
- BDJRBEYXGGNYIS-UHFFFAOYSA-N nonanedioic acid Chemical compound OC(=O)CCCCCCCC(O)=O BDJRBEYXGGNYIS-UHFFFAOYSA-N 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000012860 organic pigment Substances 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- KQDIGHIVUUADBZ-PEDHHIEDSA-N pentigetide Chemical compound OC(=O)C[C@H](N)C(=O)N[C@@H](CO)C(=O)N[C@@H](CC(O)=O)C(=O)N1CCC[C@H]1C(=O)N[C@@H](CCCNC(N)=N)C(O)=O KQDIGHIVUUADBZ-PEDHHIEDSA-N 0.000 description 1
- 239000002530 phenolic antioxidant Substances 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920000166 polytrimethylene carbonate Polymers 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 150000007944 thiolates Chemical class 0.000 description 1
- 239000012974 tin catalyst Substances 0.000 description 1
- KSBAEPSJVUENNK-UHFFFAOYSA-L tin(ii) 2-ethylhexanoate Chemical compound [Sn+2].CCCCC(CC)C([O-])=O.CCCCC(CC)C([O-])=O KSBAEPSJVUENNK-UHFFFAOYSA-L 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 238000005809 transesterification reaction Methods 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
- 239000010456 wollastonite Substances 0.000 description 1
- 229910052882 wollastonite Inorganic materials 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- PAPBSGBWRJIAAV-UHFFFAOYSA-N ε-Caprolactone Chemical compound O=C1CCCCCO1 PAPBSGBWRJIAAV-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
- D01D5/30—Conjugate filaments; Spinnerette packs therefor
- D01D5/34—Core-skin structure; Spinnerette packs therefor
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/70—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyurethanes
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/16—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one other macromolecular compound obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds as constituent
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/292—Conjugate, i.e. bi- or multicomponent, fibres or filaments
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
- D03D15/56—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads elastic
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
- D04B1/18—Other fabrics or articles characterised primarily by the use of particular thread materials elastic threads
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/4358—Polyurethanes
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43825—Composite fibres
- D04H1/43828—Composite fibres sheath-core
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/009—Condensation or reaction polymers
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/10—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyurethanes
Definitions
- the present technology relates to bicomponent fibers and fabrics made therefrom, in particular, core-sheath fibers, made from two different thermoplastic polyurethanes to provide a fiber having unique properties.
- the present invention relates to a bicomponent fiber, wherein the bicomponent fiber has a core and sheath structure, wherein the bicomponent fiber comprises (a) a core comprising a first polyester thermoplastic polyurethane which has a melting enthalpy of at least 50 J/g measured according to ASTM D3418 and (b) a sheath comprising a second polyester thermoplastic polyurethane which has a melting enthalpy of 5 J/g or less measured according to ASTM D3418.
- the present invention also relates to fabrics made from the bicomponent fibers of the present invention.
- bicomponent fiber refers to a conjugated product of at least two melt-spinnable components, wherein the conjugated product has at least two different longitudinally coextensive polymeric segments.
- the bicomponent fiber of the present invention comprises two different polymer materials intimately adhered to each other along the length of the fiber, so that the fiber cross-section is for example, a core-sheath arrangement.
- the bicomponent fiber of the present invention is made from two different polyester thermoplastic polyurethanes.
- a thermoplastic polyurethane is generally prepared by reacting a polyisocyanate with a polyol intermediate, and optionally a chain extender all of which are well known to those skilled in the art.
- the bicomponent fiber of the present invention uses two different thermoplastic polyurethane materials, each based on a different polyester polyol intermediate.
- Hydroxyl terminated polyester intermediates are generally a linear polyesters having a number average molecular weight (Mn) of from about 500 to about 10,000, desirably from about 700 to about 5,000, and preferably from about 700 to about 4,000, an acid number generally less than 1.3 and preferably less than 0.8.
- Mn number average molecular weight
- the molecular weight is determined by assay of the terminal functional groups and is related to the number average molecular weight.
- polyester polyols are produced by (1) an esterification reaction of one or more glycols with one or more dicarboxylic acids or anhydrides or (2) by transesterification reaction, i.e., the reaction of one or more glycols with esters of dicarboxylic acids. Mole ratios generally in excess of more than one mole of glycol to acid are preferred so as to obtain linear chains having a preponderance of terminal hydroxyl groups.
- Suitable polyester intermediates also include various lactones such as polycaprolactone typically made from E-caprolactone and a bifunctional initiator such as diethylene glycol.
- the dicarboxylic acids of the desired polyester can be aliphatic, cycloaliphatic, aromatic, or combinations thereof.
- Suitable dicarboxylic acids which may be used alone or in mixtures generally have a total of from 4 to 15 carbon atoms and include: succinic, glutaric, adipic, pimelic, suberic, azelaic, sebacic, dodecanedioic, isophthalic, terephthalic, cyclohexane dicarboxylic, and the like.
- Anhydrides of the above dicarboxylic acids such as phthalic anhydride, tetrahydrophthalic anhydride, or the like, can also be used.
- the glycols which are reacted to form a desirable polyester intermediate can be aliphatic, aromatic, or combinations thereof, and have a total of from 2 to 12 carbon atoms, and include ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 2,2-dimethyl-1,3-propanediol, 1,4-cyclohexanedimethanol, decamethylene glycol, dodecamethylene glycol, and the like.
- the fiber of the present invention includes a first thermoplastic polyurethane based on the butanediol succinate and a second thermoplastic polyurethane based on butanediol adipate.
- Thermoplastic polyurethanes used in the present invention are made using a polyisocyanate component.
- the polyisocyanate component includes one or more diisocyanates.
- Useful polyisocyanates may be selected from aromatic polyisocyanates or aliphatic polyisocyanates or combinations thereof.
- polyisocyanates include, but are not limited to aromatic diisocyanates such as 4,4′′-methylenebis(phenyl isocyanate) (MDI), m-xylene diisocyanate (XDI), phenylene-1,4-diisocyanate, 3,3′-dimethyl-4,4′-biphenylene diisocyanate (TODI), 1,5-naphthalene diisocyanate (NDI), and toluene diisocyanate (TDI), as well as aliphatic diisocyanates such as isophorone diisocyanate (IPDI), 1,6-hexamethylene diisocyanate (HDI), 1,4-cyclohexyl diisocyanate (CHDI), decane-1,10-diiso-cyanate, lysine diisocyanate (LDI), 1,4-butane diisocyanate (BDI), and dicyclohexylmethane-4,4′-d
- the polyisocyanate component comprises or consists of one or more aromatic diisocyanates. In some embodiments, the polyisocyanate component is essentially free of, or even completely free of, aliphatic diisocyanates.
- thermoplastic polyurethane compositions described herein are optionally made using a chain extender component.
- Chain extenders include may include diols, diamines, and combination thereof.
- Suitable chain extenders include relatively small polyhydroxy compounds, for example lower aliphatic or short chain glycols having from 2 to 20, or 2 to 12, or 2 to 10 carbon atoms.
- Suitable examples include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol (BDO), 1,6-hexanediol (HDO), 1,3-butanediol, 1,5-pentanediol, neopentylglycol, 1,4-cyclohexanedimethanol (CHDM), 2,2-bis[4-(2-hydroxyethoxy) phenyl]propane (HEPP), hexamethylenediol, heptanediol, nonanediol, dodecanediol, 3-methyl-1,5-pentanediol, ethylenediamine, butanediamine, hexamethylenediamine, and hydroxyethyl
- the above three necessary ingredients are preferably reacted in the presence of a catalyst.
- any conventional catalyst can be utilized to react the diisocyanate with the hydroxyl terminated intermediate or the chain extender and the same is well known to the art and to the literature.
- suitable catalysts include the various alkyl ethers or alkyl thiol ethers of bismuth or tin wherein the alkyl portion has from 1 to about 20 carbon atoms with specific examples including bismuth octoate, bismuth laurate, and the like.
- Preferred catalysts include the various tin catalysts such as stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate, and the like. The amount of such catalyst is generally small such as from about 20 to about 200 parts per million based upon the total weight of the polyurethane forming monomers.
- thermoplastic polyurethanes of this invention can be made by any of the conventional polymerization methods well known in the art and literature.
- Thermoplastic polyurethanes of the present invention are preferably made via a “one shot” process wherein all the components are added together simultaneously or substantially simultaneously to a heated extruder and reacted to form the polyurethane.
- the equivalent ratio of the diisocyanate to the total equivalents of the hydroxyl terminated intermediate and the diol chain extender is generally from about 0.95 to about 1.10, desirably from about 0.97 to about 1.03, and preferably from about 0.97 to about 1.00.
- the molecular weight (Mw) of thermoplastic polyurethanes useful in the present invention may be from about 50,000 Daltons to about 300,000 Daltons, for example, 50,000 Daltons to about 100,000 Daltons as measured by GPC relative to polystyrene standards.
- thermoplastic polyurethane used for the sheath in the bicomponent fiber of the present invention has a molecular weight of about 50,000 Daltons to 75,000 Daltons. In one embodiment, the thermoplastic polyurethane used for the core in the bicomponent fiber of the present invention has a molecular weight of about 80,000 Daltons to about 100,000 Daltons.
- thermoplastic polyurethanes can also be prepared utilizing a pre-polymer process.
- the hydroxyl terminated intermediate is reacted with generally an equivalent excess of one or more polyisocyanates to form a pre-polymer solution having free or unreacted polyisocyanate therein.
- a selective type of chain extender as noted above is added in an equivalent amount generally equal to the isocyanate end groups as well as to any free or unreacted diisocyanate compounds.
- the overall equivalent ratio of the total diisocyanate to the total equivalent of the hydroxyl terminated intermediate and the chain extender is thus from about 0.95 to about 1.10, desirably from about 0.98 to about 1.05 and preferably from about 0.99 to about 1.03.
- the pre-polymer route can be carried out in any conventional device with an extruder being preferred.
- the hydroxyl terminated intermediate is reacted with an equivalent excess of a diisocyanate in a first portion of the extruder to form a pre-polymer solution and subsequently the chain extender is added at a downstream portion and reacted with the pre-polymer solution.
- Any conventional extruder can be utilized, with extruders equipped with barrier screws having a length to diameter ratio of at least 20 and preferably at least 25.
- Useful additives can be utilized in suitable amounts and include opacifying pigments, colorants, mineral fillers, stabilizers, lubricants, UV absorbers, processing aids, and other additives as desired.
- Useful opacifying pigments include titanium dioxide, zinc oxide, and titanate yellow
- useful tinting pigments include carbon black, yellow oxides, brown oxides, raw and burnt sienna or umber, chromium oxide green, cadmium pigments, chromium pigments, and other mixed metal oxide and organic pigments.
- Useful fillers include diatomaceous earth (superfloss) clay, silica, talc, mica, wollastonite, barium sulfate, and calcium carbonate.
- useful stabilizers such as antioxidants can be used and include phenolic antioxidants, while useful photostabilizers include organic phosphates, and organotin thiolates (mercaptides).
- useful lubricants include metal stearates, paraffin oils and amide waxes.
- Useful UV absorbers include 2-(2′-hydroxyphenol) benzotriazoles and 2-hydroxybenzophenones.
- Plasticizer additives can also be utilized advantageously to reduce hardness without affecting properties.
- FIG. 1 illustrates the typical bicomponent melt spinning technique with a pair of extruders.
- the steps for making the bicomponent fibers include vacuum batch drying at 80° C. for 12 hours, feeding of dried thermoplastic polyurethane polymers into extruder from a hopper, melting the first and second thermoplastic polyurethane compositions in respective extruders with 1.24 inch single screw and an L/D of 24, and extruding the melts using two feeding systems/conduits by a melt pump and then to a spinneret or die.
- the back pressure at the extruder outlet was kept constant with a loop control.
- the extruder had four heating zones that were maintained between 180° C.
- the basic system consists of two feeding systems, two polymers to the spin packs and a distribution system to meter both polymers to the die. It should be understood by those skilled in the art that the spinneret for producing bicomponent or multicomponent filaments is known in the industry. Such a process is described in US Patent No. 5,162,074, which is incorporated herein by reference. Typically, spinneret includes a casing containing spin packs, plurality of plates to create a pattern for polymer to flow.
- the bicomponent continuous filament spinnerets may also be configured for extrudate to have desired cross-sections such as symmetrical (concentric) core/sheath, asymmetrical core/sheath, side-by-side, crescent shaped and the like. Additionally, multiple extruders can be added to increase the number of components.
- the fiber exits the spinneret it is cooled before winding onto bobbins.
- the fiber is passed over a set of godets, finish oil is applied, and the fiber proceeds to another set of godets.
- the thermoplastic polyurethane described above may be crosslinked with a crosslinking agent.
- Crosslinking agents are generally a pre-polymer of a hydroxyl terminated intermediate that is a polyether, polyester, polycarbonate, polycaprolactone, or mixture thereof reacted with a polyisocyanate.
- Crosslinking agents also referred to as pre-polymers in some cases, often will have an isocyanate functionality of greater than about 1.0, preferably from about 1.0 to about 3.0, and more preferably from about 1.8 to about 2.2,
- bicomponent fiber is formed without the use of crosslinking agents.
- both the core thermoplastic polyurethane and the sheath thermoplastic polyurethane are free of crosslinking.
- the bicomponent fibers of this invention can be made in a variety of denier. Denier is a term in the art designating the fiber size. Denier is the weight in grams of 9000 meters of fiber length.
- the bicomponent fibers of this invention are typically made in sizes ranging from, 20 to 2500 denier, for example 20 to 600 denier, furtherfor example 40 to 400 denier.
- anti-tack additives such as finish oils, an example of which are silicone oils, are usually added to the surface of the fibers after or during cooling and just prior to being wound into bobbins.
- a bicomponent fiber in accordance with the present invention has a core and sheath structure, wherein the bicomponent fiber has a core comprising a first polyester thermoplastic polyurethane, wherein the first polyester thermoplastic polyurethane has a melting enthalpy of at least about 50 J/g, for example, about 60 J/g, measured according to ASTM D3418 (DSC, second heat cycle) and a sheath comprising a second polyester thermoplastic polyurethane, wherein the second polyester thermoplastic polyurethane has a melting enthalpy of about 5 J/g or less measured according to ASTM D3418 (DSC, second heat cycle).
- the first polyester thermoplastic polyurethane has a contact clarity of 4% or less as measured according to ASTM D1003.
- the second polyester thermoplastic polyurethane has a contact clarity of at least 12% measured according to ASTM D1003.
- the bicomponent fiber of the present invention contains a core thermoplastic polyurethane and a sheath thermoplastic polyurethane, where the core and the sheath thermoplastic polyurethane materials are different from each other.
- the core thermoplastic polyurethane comprises the reaction product of butanediol succinate and an aromatic diisocyanate while the sheath thermoplastic polyurethane comprises the reaction product of butanediol adipate, an aromatic diisocyanate, and at least one chain extender glycol.
- the bicomponent fiber comprises about 10% to about 35% by weight of the core thermoplastic polyurethane composition and about 65% to about 90% by weight of the second thermoplastic polyurethane.
- the final bicomponent fiber has low shrinkage and good clarity.
- the present invention provides these properties surprisingly by combining two different thermoplastic polyurethane materials having different shrinkage and clarity properties.
- the core comprises a thermoplastic polyurethane composition having a melting enthalpy of at least 50J/g measured according to ASTM D3418 and a contact clarity of about 4% or less as measured according to ASTM D1003 and the sheath comprises a thermoplastic polyurethane composition having a melting enthalpy of about 5 J/g or less measured according to ASTM D3418 (DSC, second heat cycle) and a contact clarity of at least 12% measured according to ASTM D1003.
- the core thermoplastic polyurethane has a shrinkage of less than about 10% after 90 seconds exposure at 70 ° C.
- the sheath thermoplastic polyurethane has a shrinkage of about 40% to about 60% after 90 seconds exposure at 70 ° C. Shrinkage is measured by using a one meter long length of the fiber and measuring it before and after exposure to the elevated temperature. The difference between the two measurements is the shrinkage.
- the present invention also includes a fabric comprising the bicomponent fiber of the present invention.
- the fabric comprises a bicomponent fiber, wherein the bicomponent fiber has a core and sheath structure, wherein the core comprises a thermoplastic polyurethane composition having a melting enthalpy of at least about 50 J/g, for example about 60 J/g, measured according to ASTM D3418 (DSC, second heat cycle) and a contact clarity of 4% or less as measured according to ASTM D1003 and the sheath comprises a thermoplastic polyurethane composition having a melting enthalpy of about 5 J/g or less measured according to ASTM D3418 (DSC, second heat cycle) and a contact clarity of at least about 12% measured according to ASTM D1003.
- the core comprises a thermoplastic polyurethane composition having a melting enthalpy of at least about 50 J/g, for example about 60 J/g, measured according to ASTM D3418 (DSC, second heat cycle) and a contact clarity of
- the core thermoplastic polyurethane composition has a shrinkage of less than about 10% after 90 seconds exposure at 70 ° C. and the sheath thermoplastic polyurethane composition has a shrinkage of about 40% to about 60% after 90 seconds exposure at 70 ° C.
- the bicomponent fiber comprises a core to sheath ratio of 10:90 to 35:65. 5.
- the fabric of the present invention comprises a bicomponent fiber that has a shrinkage after 90 seconds of exposure at 70 ° C. of less than about 20% and a contact clarity measured according to ASTM D1003 of greater than about 13%.
- the bicomponent fiber used in the fabric may also have a melting range of 100 ° C. to 120 ° C. measured by DSC.
- Fabric made using the fibers of this invention can be made by knitting or weaving.
- fabrics can be made by using the bicomponent fibers of the present invention with other fibers, such as nylon and/or polyester.
- the fabrics of the present invention may be used to make garments, such as for sports apparel applications.
- the enhanced clarity of the fibers of the present invention also provides benefits for applications where graphics are applied to the fabrics.
- TPU 1 is a polyester thermoplastic polyurethane comprising the reaction product of butanediol succinate and an aromatic diisocyanate having a melt enthalpy measured by DSC, second heat cycle of 60 J/g.
- TPU 2 is a polyester thermoplastic polyurethane comprising the reaction product of butanediol adipate, an aromatic diisocyanate, and a chain extender diol having a melt enthalpy measured by DSC, second heat cycle of 5 J/g.
- Comparative Examples C1-C9 were made from either 100% of one TPU material or blends of pellets of TPU 1 and TPU 2 to form a mono-component filament.
- Inventive Examples 1-4 are bicomponent fibers having a core-sheath cross section. When fibers were able to be successfully made, these were tested for shrinkage using a one meter length of fiber that was measured before and after exposure to a temperature of 70° C. for 90 seconds.
- blends of two incompatible thermoplastic polyurethanes could not form a continuous filament with both acceptable shrinkage and clarity.
- bicomponent fibers of the same two thermoplastic polyurethane compositions unexpectedly provided both high clarity and low shrinkage.
- the transitional term “comprising,” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, un-recited elements or method steps.
- the term also encompass, as alternative embodiments, the phrases “consisting essentially of” and “consisting of,” where “consisting of” excludes any element or step not specified and “consisting essentially of” permits the inclusion of additional un-recited elements or steps that do not materially affect the essential or basic and novel characteristics of the composition or method under consideration.
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Abstract
The present invention relates to a bicomponent fiber, wherein the fiber has a core and sheath structure. The bicomponent fiber is made from two different polyester thermo-plastic polyurethanes to provide a fiber with enhanced clarity and low shrinkage.
Description
- The present technology relates to bicomponent fibers and fabrics made therefrom, in particular, core-sheath fibers, made from two different thermoplastic polyurethanes to provide a fiber having unique properties.
- The present invention relates to a bicomponent fiber, wherein the bicomponent fiber has a core and sheath structure, wherein the bicomponent fiber comprises (a) a core comprising a first polyester thermoplastic polyurethane which has a melting enthalpy of at least 50 J/g measured according to ASTM D3418 and (b) a sheath comprising a second polyester thermoplastic polyurethane which has a melting enthalpy of 5 J/g or less measured according to ASTM D3418.
- The present invention also relates to fabrics made from the bicomponent fibers of the present invention.
- The term “bicomponent fiber” as used herein, refers to a conjugated product of at least two melt-spinnable components, wherein the conjugated product has at least two different longitudinally coextensive polymeric segments. In one embodiment, the bicomponent fiber of the present invention comprises two different polymer materials intimately adhered to each other along the length of the fiber, so that the fiber cross-section is for example, a core-sheath arrangement.
- The bicomponent fiber of the present invention is made from two different polyester thermoplastic polyurethanes. A thermoplastic polyurethane is generally prepared by reacting a polyisocyanate with a polyol intermediate, and optionally a chain extender all of which are well known to those skilled in the art.
- The bicomponent fiber of the present invention uses two different thermoplastic polyurethane materials, each based on a different polyester polyol intermediate. Hydroxyl terminated polyester intermediates are generally a linear polyesters having a number average molecular weight (Mn) of from about 500 to about 10,000, desirably from about 700 to about 5,000, and preferably from about 700 to about 4,000, an acid number generally less than 1.3 and preferably less than 0.8. The molecular weight is determined by assay of the terminal functional groups and is related to the number average molecular weight. These polyester polyols are produced by (1) an esterification reaction of one or more glycols with one or more dicarboxylic acids or anhydrides or (2) by transesterification reaction, i.e., the reaction of one or more glycols with esters of dicarboxylic acids. Mole ratios generally in excess of more than one mole of glycol to acid are preferred so as to obtain linear chains having a preponderance of terminal hydroxyl groups. Suitable polyester intermediates also include various lactones such as polycaprolactone typically made from E-caprolactone and a bifunctional initiator such as diethylene glycol. The dicarboxylic acids of the desired polyester can be aliphatic, cycloaliphatic, aromatic, or combinations thereof. Suitable dicarboxylic acids which may be used alone or in mixtures generally have a total of from 4 to 15 carbon atoms and include: succinic, glutaric, adipic, pimelic, suberic, azelaic, sebacic, dodecanedioic, isophthalic, terephthalic, cyclohexane dicarboxylic, and the like. Anhydrides of the above dicarboxylic acids such as phthalic anhydride, tetrahydrophthalic anhydride, or the like, can also be used. The glycols which are reacted to form a desirable polyester intermediate can be aliphatic, aromatic, or combinations thereof, and have a total of from 2 to 12 carbon atoms, and include ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 2,2-dimethyl-1,3-propanediol, 1,4-cyclohexanedimethanol, decamethylene glycol, dodecamethylene glycol, and the like.
- In one embodiment, the fiber of the present invention includes a first thermoplastic polyurethane based on the butanediol succinate and a second thermoplastic polyurethane based on butanediol adipate.
- Thermoplastic polyurethanes used in the present invention are made using a polyisocyanate component. In some embodiments, the polyisocyanate component includes one or more diisocyanates. Useful polyisocyanates may be selected from aromatic polyisocyanates or aliphatic polyisocyanates or combinations thereof. Examples of useful polyisocyanates include, but are not limited to aromatic diisocyanates such as 4,4″-methylenebis(phenyl isocyanate) (MDI), m-xylene diisocyanate (XDI), phenylene-1,4-diisocyanate, 3,3′-dimethyl-4,4′-biphenylene diisocyanate (TODI), 1,5-naphthalene diisocyanate (NDI), and toluene diisocyanate (TDI), as well as aliphatic diisocyanates such as isophorone diisocyanate (IPDI), 1,6-hexamethylene diisocyanate (HDI), 1,4-cyclohexyl diisocyanate (CHDI), decane-1,10-diiso-cyanate, lysine diisocyanate (LDI), 1,4-butane diisocyanate (BDI), and dicyclohexylmethane-4,4′-diisocyanate (H12MDI). In some embodiments, mixtures of two or more polyisocyanates may be used.
- In some embodiments, the polyisocyanate component comprises or consists of one or more aromatic diisocyanates. In some embodiments, the polyisocyanate component is essentially free of, or even completely free of, aliphatic diisocyanates.
- The thermoplastic polyurethane compositions described herein are optionally made using a chain extender component. Chain extenders include may include diols, diamines, and combination thereof.
- Suitable chain extenders include relatively small polyhydroxy compounds, for example lower aliphatic or short chain glycols having from 2 to 20, or 2 to 12, or 2 to 10 carbon atoms. Suitable examples include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol (BDO), 1,6-hexanediol (HDO), 1,3-butanediol, 1,5-pentanediol, neopentylglycol, 1,4-cyclohexanedimethanol (CHDM), 2,2-bis[4-(2-hydroxyethoxy) phenyl]propane (HEPP), hexamethylenediol, heptanediol, nonanediol, dodecanediol, 3-methyl-1,5-pentanediol, ethylenediamine, butanediamine, hexamethylenediamine, and hydroxyethyl resorcinol (HER), and the like, as well as mixtures thereof.
- The above three necessary ingredients (hydroxyl terminated intermediate, polyisocyanate, and chain extender) are preferably reacted in the presence of a catalyst.
- Generally, any conventional catalyst can be utilized to react the diisocyanate with the hydroxyl terminated intermediate or the chain extender and the same is well known to the art and to the literature. Examples of suitable catalysts include the various alkyl ethers or alkyl thiol ethers of bismuth or tin wherein the alkyl portion has from 1 to about 20 carbon atoms with specific examples including bismuth octoate, bismuth laurate, and the like. Preferred catalysts include the various tin catalysts such as stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate, and the like. The amount of such catalyst is generally small such as from about 20 to about 200 parts per million based upon the total weight of the polyurethane forming monomers.
- The thermoplastic polyurethanes of this invention can be made by any of the conventional polymerization methods well known in the art and literature.
- Thermoplastic polyurethanes of the present invention are preferably made via a “one shot” process wherein all the components are added together simultaneously or substantially simultaneously to a heated extruder and reacted to form the polyurethane. The equivalent ratio of the diisocyanate to the total equivalents of the hydroxyl terminated intermediate and the diol chain extender is generally from about 0.95 to about 1.10, desirably from about 0.97 to about 1.03, and preferably from about 0.97 to about 1.00. The molecular weight (Mw) of thermoplastic polyurethanes useful in the present invention may be from about 50,000 Daltons to about 300,000 Daltons, for example, 50,000 Daltons to about 100,000 Daltons as measured by GPC relative to polystyrene standards. In one embodiment, the thermoplastic polyurethane used for the sheath in the bicomponent fiber of the present invention has a molecular weight of about 50,000 Daltons to 75,000 Daltons. In one embodiment, the thermoplastic polyurethane used for the core in the bicomponent fiber of the present invention has a molecular weight of about 80,000 Daltons to about 100,000 Daltons.
- The thermoplastic polyurethanes can also be prepared utilizing a pre-polymer process. In the pre-polymer route, the hydroxyl terminated intermediate is reacted with generally an equivalent excess of one or more polyisocyanates to form a pre-polymer solution having free or unreacted polyisocyanate therein. Subsequently, a selective type of chain extender as noted above is added in an equivalent amount generally equal to the isocyanate end groups as well as to any free or unreacted diisocyanate compounds. The overall equivalent ratio of the total diisocyanate to the total equivalent of the hydroxyl terminated intermediate and the chain extender is thus from about 0.95 to about 1.10, desirably from about 0.98 to about 1.05 and preferably from about 0.99 to about 1.03. Typically, the pre-polymer route can be carried out in any conventional device with an extruder being preferred. Thus, the hydroxyl terminated intermediate is reacted with an equivalent excess of a diisocyanate in a first portion of the extruder to form a pre-polymer solution and subsequently the chain extender is added at a downstream portion and reacted with the pre-polymer solution. Any conventional extruder can be utilized, with extruders equipped with barrier screws having a length to diameter ratio of at least 20 and preferably at least 25.
- Useful additives can be utilized in suitable amounts and include opacifying pigments, colorants, mineral fillers, stabilizers, lubricants, UV absorbers, processing aids, and other additives as desired. Useful opacifying pigments include titanium dioxide, zinc oxide, and titanate yellow, while useful tinting pigments include carbon black, yellow oxides, brown oxides, raw and burnt sienna or umber, chromium oxide green, cadmium pigments, chromium pigments, and other mixed metal oxide and organic pigments. Useful fillers include diatomaceous earth (superfloss) clay, silica, talc, mica, wollastonite, barium sulfate, and calcium carbonate. If desired, useful stabilizers such as antioxidants can be used and include phenolic antioxidants, while useful photostabilizers include organic phosphates, and organotin thiolates (mercaptides). Useful lubricants include metal stearates, paraffin oils and amide waxes. Useful UV absorbers include 2-(2′-hydroxyphenol) benzotriazoles and 2-hydroxybenzophenones.
- Plasticizer additives can also be utilized advantageously to reduce hardness without affecting properties.
- Bicomponent continuous filaments of the present invention can be made using a melt-spinning process.
FIG. 1 illustrates the typical bicomponent melt spinning technique with a pair of extruders. The steps for making the bicomponent fibers include vacuum batch drying at 80° C. for 12 hours, feeding of dried thermoplastic polyurethane polymers into extruder from a hopper, melting the first and second thermoplastic polyurethane compositions in respective extruders with 1.24 inch single screw and an L/D of 24, and extruding the melts using two feeding systems/conduits by a melt pump and then to a spinneret or die. The back pressure at the extruder outlet was kept constant with a loop control. The extruder had four heating zones that were maintained between 180° C. — 220° C. The basic system consists of two feeding systems, two polymers to the spin packs and a distribution system to meter both polymers to the die. It should be understood by those skilled in the art that the spinneret for producing bicomponent or multicomponent filaments is known in the industry. Such a process is described in US Patent No. 5,162,074, which is incorporated herein by reference. Typically, spinneret includes a casing containing spin packs, plurality of plates to create a pattern for polymer to flow. The bicomponent continuous filament spinnerets may also be configured for extrudate to have desired cross-sections such as symmetrical (concentric) core/sheath, asymmetrical core/sheath, side-by-side, crescent shaped and the like. Additionally, multiple extruders can be added to increase the number of components. - Once the fiber exits the spinneret, it is cooled before winding onto bobbins. The fiber is passed over a set of godets, finish oil is applied, and the fiber proceeds to another set of godets.
- In some embodiments, during the melt spinning process, the thermoplastic polyurethane described above may be crosslinked with a crosslinking agent. Crosslinking agents are generally a pre-polymer of a hydroxyl terminated intermediate that is a polyether, polyester, polycarbonate, polycaprolactone, or mixture thereof reacted with a polyisocyanate. Crosslinking agents (also referred to as pre-polymers in some cases), often will have an isocyanate functionality of greater than about 1.0, preferably from about 1.0 to about 3.0, and more preferably from about 1.8 to about 2.2,
- In one embodiment of the present invention, bicomponent fiber is formed without the use of crosslinking agents. In this embodiment, both the core thermoplastic polyurethane and the sheath thermoplastic polyurethane are free of crosslinking.
- The bicomponent fibers of this invention can be made in a variety of denier. Denier is a term in the art designating the fiber size. Denier is the weight in grams of 9000 meters of fiber length. The bicomponent fibers of this invention are typically made in sizes ranging from, 20 to 2500 denier, for example 20 to 600 denier, furtherfor example 40 to 400 denier.
- When bicomponent fibers are made by the process of this invention, anti-tack additives such as finish oils, an example of which are silicone oils, are usually added to the surface of the fibers after or during cooling and just prior to being wound into bobbins.
- A bicomponent fiber in accordance with the present invention has a core and sheath structure, wherein the bicomponent fiber has a core comprising a first polyester thermoplastic polyurethane, wherein the first polyester thermoplastic polyurethane has a melting enthalpy of at least about 50 J/g, for example, about 60 J/g, measured according to ASTM D3418 (DSC, second heat cycle) and a sheath comprising a second polyester thermoplastic polyurethane, wherein the second polyester thermoplastic polyurethane has a melting enthalpy of about 5 J/g or less measured according to ASTM D3418 (DSC, second heat cycle). In one embodiment of this bicomponent fiber, the first polyester thermoplastic polyurethane has a contact clarity of 4% or less as measured according to ASTM D1003. In another embodiment of this bicomponent fiber, the second polyester thermoplastic polyurethane has a contact clarity of at least 12% measured according to ASTM D1003.
- The bicomponent fiber of the present invention contains a core thermoplastic polyurethane and a sheath thermoplastic polyurethane, where the core and the sheath thermoplastic polyurethane materials are different from each other. In one embodiment, the core thermoplastic polyurethane comprises the reaction product of butanediol succinate and an aromatic diisocyanate while the sheath thermoplastic polyurethane comprises the reaction product of butanediol adipate, an aromatic diisocyanate, and at least one chain extender glycol.
- In the present invention, the bicomponent fiber comprises about 10% to about 35% by weight of the core thermoplastic polyurethane composition and about 65% to about 90% by weight of the second thermoplastic polyurethane.
- In one embodiment of the present invention, the final bicomponent fiber has low shrinkage and good clarity. For some applications, it is desired to have a bicomponent fiber having a shrinkage after 90 seconds of exposure at 70 ° C. of less than about 20% and a contact clarity measured according to ASTM D1003 of greater than about 13%. The present invention provides these properties surprisingly by combining two different thermoplastic polyurethane materials having different shrinkage and clarity properties. In one embodiment, the core comprises a thermoplastic polyurethane composition having a melting enthalpy of at least 50J/g measured according to ASTM D3418 and a contact clarity of about 4% or less as measured according to ASTM D1003 and the sheath comprises a thermoplastic polyurethane composition having a melting enthalpy of about 5 J/g or less measured according to ASTM D3418 (DSC, second heat cycle) and a contact clarity of at least 12% measured according to ASTM D1003. In another embodiment, the core thermoplastic polyurethane has a shrinkage of less than about 10% after 90 seconds exposure at 70 ° C., while the sheath thermoplastic polyurethane has a shrinkage of about 40% to about 60% after 90 seconds exposure at 70 ° C. Shrinkage is measured by using a one meter long length of the fiber and measuring it before and after exposure to the elevated temperature. The difference between the two measurements is the shrinkage.
- The present invention also includes a fabric comprising the bicomponent fiber of the present invention. In one embodiment, the fabric comprises a bicomponent fiber, wherein the bicomponent fiber has a core and sheath structure, wherein the core comprises a thermoplastic polyurethane composition having a melting enthalpy of at least about 50 J/g, for example about 60 J/g, measured according to ASTM D3418 (DSC, second heat cycle) and a contact clarity of 4% or less as measured according to ASTM D1003 and the sheath comprises a thermoplastic polyurethane composition having a melting enthalpy of about 5 J/g or less measured according to ASTM D3418 (DSC, second heat cycle) and a contact clarity of at least about 12% measured according to ASTM D1003. In one embodiment, the core thermoplastic polyurethane composition has a shrinkage of less than about 10% after 90 seconds exposure at 70 ° C. and the sheath thermoplastic polyurethane composition has a shrinkage of about 40% to about 60% after 90 seconds exposure at 70 ° C. In the fabric in accordance with the present invention, the bicomponent fiber comprises a core to sheath ratio of 10:90 to 35:65. 5.
- In another embodiment, the fabric of the present invention comprises a bicomponent fiber that has a shrinkage after 90 seconds of exposure at 70 ° C. of less than about 20% and a contact clarity measured according to ASTM D1003 of greater than about 13%. The bicomponent fiber used in the fabric may also have a melting range of 100 ° C. to 120 ° C. measured by DSC.
- Fabric made using the fibers of this invention can be made by knitting or weaving. In some embodiments, fabrics can be made by using the bicomponent fibers of the present invention with other fibers, such as nylon and/or polyester. The fabrics of the present invention may be used to make garments, such as for sports apparel applications. The enhanced clarity of the fibers of the present invention also provides benefits for applications where graphics are applied to the fabrics.
- The invention will be better understood by reference to the following examples.
- Filaments were prepared based on the thermoplastic polyurethanes listed in Table 1. TPU 1 is a polyester thermoplastic polyurethane comprising the reaction product of butanediol succinate and an aromatic diisocyanate having a melt enthalpy measured by DSC, second heat cycle of 60 J/g. TPU 2 is a polyester thermoplastic polyurethane comprising the reaction product of butanediol adipate, an aromatic diisocyanate, and a chain extender diol having a melt enthalpy measured by DSC, second heat cycle of 5 J/g. Comparative Examples C1-C9 were made from either 100% of one TPU material or blends of pellets of TPU 1 and TPU 2 to form a mono-component filament. Inventive Examples 1-4 are bicomponent fibers having a core-sheath cross section. When fibers were able to be successfully made, these were tested for shrinkage using a one meter length of fiber that was measured before and after exposure to a temperature of 70° C. for 90 seconds.
-
TABLE 1 TPI 1 TPU 2 Shrinkage Clarity (%) Example (wt %) (wt %) (%) ASTM D1003 Comments C1 100 40 12 Too high shrinkage C2 100 4 4 Very opaque C3 10 90 45-60 NA Shrinking after fusing1 C4 25 75 45 Shrinking after fusing1 C5 35 65 Filament breaks during spinning2 C6 50 50 Filament breaks during spinning2 C7 65 35 Filament breaks during spinning2 C8 75 25 Filament breaks during spinning2 C9 90 10 Filament breaks during spinning2 Inv 1 75 25 10 5 Inv 3 40 60 11 7 Inv 4 25 75 13 13 1Filaments were spun and knitted into a fabric. Heat was applied to fuse the fibers in the fabric. The fabric shrunk and deformed such that a clarity measurement could not be obtained. 2A continuous filament could not be made with these blends. Incompatibility (immiscibility non-miscibility) between the two TPU materials caused the blend to have insufficient melt strength to make a continuous filament. - As shown by the data above, blends of two incompatible thermoplastic polyurethanes could not form a continuous filament with both acceptable shrinkage and clarity. However, bicomponent fibers of the same two thermoplastic polyurethane compositions unexpectedly provided both high clarity and low shrinkage.
- Except in the Examples, or where otherwise explicitly indicated, all numerical quantities in this description specifying amounts of materials, reaction conditions, molecular weights, number of carbon atoms, and the like, are to be understood as modified by the word “about.” It is to be understood that the upper and lower amount, range, and ratio limits set forth herein may be independently combined. Similarly, the ranges and amounts for each element of the invention can be used together with ranges or amounts for any of the other elements.
- As used herein, the transitional term “comprising,” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, un-recited elements or method steps. However, in each recitation of “comprising” herein, it is intended that the term also encompass, as alternative embodiments, the phrases “consisting essentially of” and “consisting of,” where “consisting of” excludes any element or step not specified and “consisting essentially of” permits the inclusion of additional un-recited elements or steps that do not materially affect the essential or basic and novel characteristics of the composition or method under consideration.
- While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. In this regard, the scope of the invention is to be limited only by the following claims.
Claims (31)
1. A fabric comprising:
a bicomponent fiber, wherein the bicomponent fiber has a core and sheath structure, wherein the core comprises a thermoplastic polyurethane composition having a melting enthalpy of at least about 50 J/g measured according to ASTM D3418 and a contact clarity of 4% or less as measured according to ASTM D1003 and the sheath comprises a thermoplastic polyurethane composition having a melting enthalpy of about 5 J/g or less measured according to ASTM D3418 and a contact clarity of at least 12% measured according to ASTM D1003.
2. The fabric of claim 1 , wherein the core thermoplastic polyurethane composition has a shrinkage of less than 10% after 90 seconds exposure at 70° C.
3. The fabric of claim 1 , wherein the sheath thermoplastic polyurethane composition has a shrinkage of 40% to 60% after 90 seconds exposure at 70° C.
4. The fabric of claim 1 , wherein the bicomponent fiber comprises a core to sheath ratio of 10:90 to 35:65.
5. The fabric of claim 1 , wherein the bicomponent fiber has a shrinkage after 90 seconds of exposure at 70° C. of less than 20% and a contact clarity measured according to ASTM D1003 of greater than 13%.
6. The fabric of claim 1 , wherein the bicomponent fiber has a melting range of 100° C. to 120° C. measured by DSC.
7. The fabric of claim 1 , wherein the core comprises a polyester thermoplastic polyurethane.
8. The fabric of claim 1 , wherein the sheath comprises a polyester thermoplastic polyurethane that is different from the core thermoplastic polyurethane.
9. The fabric of claim 1 , wherein the core comprises a thermoplastic polyurethane comprising the reaction product of butanediol succinate and an aromatic diisocyanate.
10. The fabric of claim 9 , wherein the core comprises a thermoplastic polyurethane consisting of the reaction product of butanediol succinate and aromatic diisocyanate.
11. The fabric of claim 1 , wherein the sheath comprises a thermoplastic polyurethane comprising the reaction product of butanediol adipate, an aromatic diisocyanate, and a chain extender.
12. The fabric of claim 11 , wherein the sheath comprises a thermoplastic polyurethane consisting of the reaction product of butanediol adipate, an aromatic diisocyanate, and a chain extender.
13. The fabric of claim 1 , wherein both the core thermoplastic polyurethane and the sheath thermoplastic polyurethane are free of crosslinking.
14. The fabric of claim 1 , wherein the core comprises a thermoplastic polyurethane having a melting enthalpy of about 60 J/g.
15. The fabric of claim 1 , wherein the sheath comprises a thermoplastic polyurethane having a melting enthalpy of 5 J/g.
16. A bicomponent fiber having a core and sheath structure, wherein the bicomponent fiber comprises:
(a) a core comprising a first polyester thermoplastic polyurethane; wherein the first polyester thermoplastic polyurethane has a melting enthalpy of at least 50J/g measured according to ASTM D3418. (b) a sheath comprising a second polyester thermoplastic polyurethane, wherein the second polyester thermoplastic polyurethane has a melting enthalpy of 5 J/g or less measured according to ASTM D3418.
17. The bicomponent fiber of claim 16 , wherein the first polyester thermoplastic polyurethane has a contact clarity of 4% or less as measured according to ASTM D1003.
18. The bicomponent fiber of claim 16 , wherein the second polyester thermoplastic polyurethane has a contact clarity of at least 12% measured according to ASTM D1003.
19. The bicomponent fiber of claim 16 , wherein the first polyester thermoplastic polyurethane comprises the reaction product of butanediol succinate and an aromatic diisocyanate.
20. The bicomponent fiber of claim 16 , wherein the second polyester thermoplastic polyurethane comprises the reaction product of butanediol adipate, an aromatic diisocyanate, and a chain extender.
21. The bicomponent fiber of claims 16 , wherein the bicomponent fiber comprises 65% to 90% by weight of the second thermoplastic polyurethane.
22. The bicomponent fiber of claim 16 , wherein the bicomponent fiber comprises 10% to 35% by weight of the core thermoplastic polyurethane composition.
23. The bicomponent fiber of claim 16 , wherein the first thermoplastic polyurethane has a shrinkage of less than 10% after 90 seconds exposure at 70° C. .
24. The bicomponent fiber of claim 16 , wherein the second thermoplastic polyurethane has a shrinkage of 40% to 60% after 90 seconds exposure at 70° C.
25. The bicomponent fiber of claim 16 , wherein the first polyester thermoplastic polyurethane has a melting enthalpy of 60 J/g measured according to ASTM D3418.
26. The bicomponent fiber of claim 16 , wherein the second polyester thermoplastic polyurethane has a melting enthalpy of 5 J/g measured according to ASTM D3418.
27. The bicomponent fiber of claim 16 , wherein both the first and second thermoplastic polyurethanes are free of crosslinking.
28. A fabric comprising:
a bicomponent fiber, wherein the bicomponent fiber has a core and sheath structure, wherein the core comprises a polyester thermoplastic polyurethane comprising the reaction product of butanediol succinate and an aromatic diisocyanate and has a melting enthalpy of at least 50J/g measured according to ASTM D3418 and a contact clarity of 4% or less as measured according to ASTM D1003 and the sheath comprises a polyester thermoplastic polyurethane comprising the reaction product of butanediol adipate, an aromatic diisocyanate, and a chain extender and has a melting enthalpy of 5 J/g or less measured according to ASTM D3418 and a contact clarity of at least 12% measured according to ASTM D1003, wherein both the core thermoplastic polyurethane and the sheath thermoplastic polyurethane are free of crosslinking.
29. The fabric of claim 28 , wherein the fabric is a knitted fabric.
30. The fabric of claim 28 , wherein the fabric is a woven fabric.
31. The fabric of claim 28 , wherein the fabric is a non-woven fabric.
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US5349028A (en) * | 1992-05-11 | 1994-09-20 | Showa Highpolymer Co., Ltd. | Polyester fibers |
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US5162074A (en) | 1987-10-02 | 1992-11-10 | Basf Corporation | Method of making plural component fibers |
JPH055217A (en) * | 1991-06-24 | 1993-01-14 | Kuraray Co Ltd | Polyurethane conjugate elastic fiber |
WO1993001222A1 (en) * | 1991-07-03 | 1993-01-21 | Kanebo, Ltd. | Thermoplastic polyurethane elastomer, method and device for manufacture thereof, and elastic fiber made therefrom |
US20050245157A1 (en) * | 2004-04-30 | 2005-11-03 | Kimberly-Clark Worldwide, Inc. | Nonwoven fabrics comprising strata with differing levels or combinations of additives and process of making the same |
EP2912216B1 (en) * | 2012-10-23 | 2016-03-23 | Lubrizol Advanced Materials, Inc. | Dyeable and flame-retarded thermoplastic polyurethane fibers |
CN104797749B (en) * | 2012-11-16 | 2017-06-13 | 巴斯夫欧洲公司 | Bicomponent fibre, Preparation Method And The Use and the fabric containing the bicomponent fibre |
CN104911747B (en) * | 2015-06-03 | 2017-06-06 | 东华大学 | A kind of elastic energy storage phase change fiber and preparation method thereof |
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