US20240183082A1

US20240183082A1 - Method for manufacturing elastic fiber and elastic fiber

Info

Publication number: US20240183082A1
Application number: US18/384,557
Authority: US
Inventors: Chih-Yi Lin; Kuo-Kuang Cheng; Li-Yuan Chen; Chi-Wei Chang; Chia-Chun YANG
Original assignee: San Fang Chemical Industry Co Ltd
Current assignee: San Fang Chemical Industry Co Ltd
Priority date: 2022-12-06
Filing date: 2023-10-27
Publication date: 2024-06-06
Also published as: CN118147779A; TW202424295A; TWI828460B

Abstract

A method for manufacturing an elastic fiber and the elastic fiber are provided. The method includes: providing a thermoplastic polyester elastomer; drying the thermoplastic polyester elastomer; melting the thermoplastic polyester elastomer by an extruder to form a melt; extruding the melt by a spinneret plate to form a plurality of filamentous streams; feeding the filamentous streams into a spinning channel for cooling and curing to form a plurality of monofilaments; and bundling and oiling the monofilaments by an oil wheel, after extending and guiding the monofilaments by a first godet roller and a second godet roller, and winding the monofilaments by a winder to obtain a thermoplastic polyester elastic fiber.

Description

BACKGROUND

1. Field of the Disclosure

The present disclosure relates to a method for manufacturing an elastic fiber and the elastic fiber.

2. Description of the Related Art

Polyurethane elastic fibers are well-known in the market and widely applied to highly close-fitting and retractable products such as socks, underwear and swimwear. The reason is that the polyurethane elastic fibers are high in elongation and have strong resilience. However, the polyurethane elastic fibers are high in raw material and production cost, and have the problems of solvent pollution, difficulty in dyeing, skin allergy and the like.

SUMMARY

In some embodiments, a method for manufacturing an elastic fiber includes: providing a thermoplastic polyester elastomer; drying the thermoplastic polyester elastomer; melting the thermoplastic polyester elastomer by an extruder to form a melt; extruding the melt by a spinneret plate to form a plurality of filamentous streams; feeding the filamentous streams into a spinning channel for cooling and curing to form a plurality of monofilaments; and bundling and oiling the monofilaments by an oil wheel, after extending and guiding the monofilaments by a first godet roller and a second godet roller, and winding the monofilaments by a winder to obtain a thermoplastic polyester elastic fiber.
In some embodiments, an elastic fiber is manufactured by the above manufacturing method. The elastic fiber includes a multifilament structure.

DETAILED DESCRIPTION

The present disclosure provides a method for manufacturing an elastic fiber, including the following steps:
A thermoplastic polyester elastomer is provided. In some embodiments, the thermoplastic polyester elastomer may contain a linear block copolymer of polybutylene terephthalate and polyester or polyether. A Shore hardness of the thermoplastic polyester elastomer may be 20 D to 60 D.
The thermoplastic polyester elastomer is dried. In some embodiments, a temperature for drying the thermoplastic polyester elastomer may be 70° C. to 100° C. A time for drying the thermoplastic polyester elastomer may be 5 h to 8 h.
The thermoplastic polyester elastomer is melted by an extruder to form a melt. In some embodiments, a temperature of the extruder may be 200° ° C. to 230° C. In some embodiments, the extruder may include a plurality of heating areas (including, for example, a first heating area, a second heating area and a third heating area). The temperature of the plurality of heating areas (for example, the first heating area, the second heating area and the third heating area) may be 200° ° C. to 230° C., and the temperatures of the heating areas may be set to be the same or different.
The melt is extruded by a spinneret plate to form a plurality of filamentous streams. In some embodiments, the spinneret plate may include a plurality of holes. The melt may pass through the holes to form the filamentous streams. In some embodiments, the sizes of the holes may be adjusted according to the specification of the required elastic fiber.
The filamentous streams are fed into a spinning channel for cooling and curing to form a plurality of monofilaments. In some embodiments, cooling may be carried out in a lateral blowing manner. In some embodiments, the monofilaments may also be referred to as “fine filaments.”
The monofilaments are bundled and oiled by an oil wheel, then the monofilaments are extended and guided by a first godet roller and a second godet roller, and the monofilaments are winded by a winder to obtain a thermoplastic polyester elastic fiber. In some embodiments, a temperature of the first godet roller may be 30 to 50° ° C., and a speed of the first godet roller may be 600 to 1,500 M/min. A temperature of the second godet roller may be 30 to 50° ° C., and a speed of the second godet roller may be 600 to 1,500 M/min. A speed of the winder may be 600 to 1,500 M/min. The obtained thermoplastic polyester elastic fiber may achieve the following physical properties: a denier is 40 D to 500 D, 70 D to 350 D or 100 D to 250 D; a breaking strength is 0.8 to 1.5 g/D, 0.9 to 1.3 g/D or 1.0 to 1.2 g/D; an elongation at break is 360% to 900%, 400% to 600% or 450% to 550%; a permanent deformation value under 100% fixed elongation is 3 to 10 mm, 3 to 8 mm or 3 to 7 mm; and a permanent deformation value under 200% fixed elongation is 10 to 40 mm, 15 to 40 mm or 20 to 40 mm.
In addition, the manufactured thermoplastic polyester elastic fiber includes a multifilament structure. In some embodiments, the multifilament structure may include 6 to 48 monofilaments so as to ensure the resilience and flexibility of the thermoplastic polyester elastic fiber. In some embodiments, a cross section of the multifilament structure may be in a shape formed by stacking a plurality of perfect circles or non-perfect circles.
According to the present disclosure, the thermoplastic polyester elastic fiber obtained from the above thermoplastic polyester elastomer by using the above manufacturing method has the advantages of no solvent pollution, easy dyeing and low possibility of causing anaphylactic reaction, has high elongation and resilience, and has the characteristics of oil resistance, acid and alkali resistance, recyclability and the like. In addition, compared with a known polyurethane elastic fiber, the thermoplastic polyester elastic fiber according to the present disclosure has the advantages of simple manufacturing process and relatively cheap raw materials, can be recycled and reprocessed by matching with polyester yarns, and meets the requirement of environmental protection.
In some embodiments, the thermoplastic polyester elastic fiber according to the present disclosure may be surrounded by a plurality of peripheral fibers to form single covered yarns (SCYs), double covered yarns (DCYs), air-jetcovered yarns (ACYs) or air textured yarns (ATYs), but it is not limited to the above.
The present disclosure is illustrated in detail with the following embodiments, but it does not mean that the present disclosure is only limited to the content disclosed by these embodiments.

Embodiment 1

A thermoplastic polyester elastomer was dried at a temperature of 80° ° C. for 8 h. The temperatures of the first heating area, the second heating area and the third heating area of the extruder were set to be 200° C., 200° ° C. and 225° C., respectively. The temperatures of the first godet roller and the second godet roller were set to be 30° ° C. and the speeds of the first godet roller and the second godet roller were set to be 1,090 M/min. The speed of the winder was set to be 990 M/min.
The obtained thermoplastic polyester elastic fiber had the denier of 215 D, the breaking strength of 1.1 g/D, the elongation at break of 434%, the permanent deformation value under 100% fixed elongation of 3 mm and the permanent deformation value under 200% fixed elongation of 29 mm.

Embodiment 2

A thermoplastic polyester elastomer was dried at a temperature of 80° C. for 8 h. The temperatures of the first heating area, the second heating area and the third heating area of the extruder were set to be 200° ° C., 220° C. and 235° C., respectively. The temperatures of the first godet roller and the second godet roller were set to be 35° C. and the speeds of the first godet roller and the second godet roller were set to be 1,250 M/min. The speed of the winder was set to be 1,250 M/min.
The obtained thermoplastic polyester elastic fiber had the denier of 200 D, the breaking strength of 1.2 g/D, the elongation at break of 415%, the permanent deformation value under 100% fixed elongation of 3 mm and the permanent deformation value under 200% fixed elongation of 32 mm.

Embodiment 3

A thermoplastic polyester elastomer was dried at a temperature of 80° C. for 8 h. The temperatures of the first heating area, the second heating area and the third heating area of the extruder were set to be 200° ° C., 200° C. and 225° C., respectively. The temperatures of the first godet roller and the second godet roller were set to be 30° C. and the speeds of the first godet roller and the second godet roller were set to be 1,200 M/min. The speed of the winder was set to be 900 M/min.
The obtained thermoplastic polyester elastic fiber had the denier of 140 D, the breaking strength of 1.0 g/D, the elongation at break of 368%, the permanent deformation value under 100% fixed elongation of 7 mm and the permanent deformation value under 200% fixed elongation of 40 mm.

Embodiment 4

A thermoplastic polyester elastomer was dried at a temperature of 80° C. for 8 h. The temperatures of the first heating area, the second heating area and the third heating area of the extruder were set to be 200° ° C., 200° ° C. and 225° C., respectively. The temperatures of the first godet roller and the second godet roller were set to be 30° C. and the speeds of the first godet roller and the second godet roller were set to be 830 M/min. The speed of the winder was set to be 600 M/min.
The obtained thermoplastic polyester elastic fiber had the denier of 203 D, the breaking strength of 1.1 g/D, the elongation at break of 453%, the permanent deformation value under 100% fixed elongation of 3 mm and the permanent deformation value under 200% fixed elongation of 27 mm.
The physical properties of the thermoplastic polyester elastic fibers in Embodiments 1-4 are shown as the following Table 1. In Table 1, a denier testing method refers to ASTM D6717, a method for testing the breaking strength and the elongation at break refers to ASTM D2653, and a method for testing the permanent deformation value refers to ASTM D2731. According to the physical property result in Table 1, the elongation at break of the thermoplastic polyester elastic fibers in Embodiments 1-4 may reach over 368% (including 368%), the permanent deformation value under 100% fixed elongation may reach over 3 mm (including 3 mm), and the permanent deformation value under 200% fixed elongation may reach over 27 mm (including 27 mm), so that the thermoplastic polyester elastic fibers in Embodiments 1-4 have high elongation and high resilience.

TABLE 1

			Permanent	Permanent
			deformation value	deformation value
	Breaking	Elongation	under 100% fixed	under 200% fixed
Denier	strength	at break	elongation	elongation

Embodiment 1	215D	1.1 g/D	434%	3 mm	29 mm
Embodiment 2	200D	1.2 g/D	415%	3 mm	32 mm
Embodiment 3	140D	1.0 g/D	368%	7 mm	40 mm
Embodiment 4	203D	1.1 g/D	453%	3 mm	27 mm

While several embodiments of the present disclosure have been illustrated and described, various modifications and improvements can be made by those skilled in the art. The embodiments of the present disclosure are therefore described in an illustrative but not in a restrictive sense. It is intended that the present disclosure should not be limited to the particular forms as illustrated and that all modifications which maintain the spirit and scope of the present disclosure are within the scope defined in the appended claims.

Claims

What is claimed is:

1. A method for manufacturing an elastic fiber, comprising:

providing a thermoplastic polyester elastomer;

drying the thermoplastic polyester elastomer;

melting the thermoplastic polyester elastomer by an extruder to form a melt;

extruding the melt by a spinneret plate to form a plurality of filamentous streams;

feeding the filamentous streams into a spinning channel for cooling and curing to form a plurality of monofilaments; and

bundling and oiling the monofilaments by an oil wheel, after extending and guiding the monofilaments by a first godet roller and a second godet roller, and winding the monofilaments by a winder to obtain a thermoplastic polyester elastic fiber.

2. The method of claim 1, wherein the thermoplastic polyester elastomer contains a linear block copolymer of polybutylene terephthalate and polyester or polyether.

3. The method of claim 1, wherein a Shore hardness of the thermoplastic polyester elastomer is 20 D to 60 D.

4. The method of claim 1, wherein a temperature of the extruder is 200° ° C. to 230° C., and a speed of the winder is 600 to 1,500 M/min.

5. The method of claim 1, wherein a temperature of the first godet roller is 30 to 50° C., a speed of the first godet roller is 600 to 1,500 M/min, a temperature of the second godet roller is 30 to 50° C., and a speed of the second godet roller is 600 to 1,500 M/min.

6. An elastic fiber, which is manufactured by the method according to claim 1 and includes a multifilament structure.

7. The elastic fiber of claim 6, wherein a cross section of the multifilament structure is in a shape formed by stacking a plurality of perfect circles or non-perfect circles.

8. The elastic fiber of claim 6, wherein the multifilament structure includes 6 to 48 monofilaments.

9. The elastic fiber of claim 6, wherein the elastic fiber has a denier of 40 D to 500 D, a breaking strength of 0.8 to 1.5 g/D, an elongation at break of 360% to 900%, a permanent deformation value under 100% fixed elongation of 3 to 10 mm, and a permanent deformation value under 200% fixed elongation of 10 to 40 mm.