Thermoplastic elastomer-based multifilament yarn

Abstract

A thermoplastic elastomer-based multifilament yarn and a method of making a thermoplastic elastomer-based multifilament yarn are disclosed. The multifilament yarn includes a first filament at least partially adhered to a second filament. The first filament and the second filament are each formed from a thermoplastic elastomer composition comprising a thermoplastic elastomer exhibiting a flexural modulus of about 300 MPa or less as determined at a temperature of about 23 DEG C according to ISO 178: 2019. The yarn has a linear density of from about 1 to about 500 deniers per filament, and exhibits an elongation at break of about 300% or greater as determined at a temperature of about 23 DEG C according to ASTM D2653-07 (2018).

Description

Cross Reference to Related Applications

[0001] This application claims the benefit of filing date of U.S. Provisional Patent Application No. 63 / 498,862, filed April 28, 2023, which is incorporated by reference herein in its entirety. BACKGROUND

[0002] Non-stretch yarns such as polyester as well as nylon are commonly used to manufacture articles such as fabrics and upholstery. Filaments used to manufacture such yarns can be spun while minimizing filament breakage, and the corresponding breakage can also be minimized during fabric processing. Another class of materials, i.e., thermoplastic elastomers, have recently been used for various applications because they are capable of being used as thermoplastics, particularly capable of being re-shaped upon heating, while also exhibiting certain typical properties of elastomers. Thus, these materials can also be used as elastomeric stretch yarns for forming various articles. However, these yarns can have a higher than desired tendency to break during spinning and / or further processing. Further, when using a multifilament yarn made from such thermoplastic elastomers, individual filaments can separate from the bundle of yarns during unwinding and / or further processing, thereby compromising the integrity of the yarn and the resulting article.

[0003] Accordingly, there remains a need to overcome certain problems associated with using thermoplastic elastomers in order to provide improved thermoplastic elastomeric multifilaments, as well as resulting yarns and articles. SUMMARY

[0004] According to one embodiment of the present disclosure, a multifilament yarn is disclosed. The multifilament yarn includes a first filament at least partially adhered to a second filament. The first filament and the second filament are each formed from a thermoplastic elastomer composition including a thermoplastic elastomer that exhibits a flexural modulus of about 300 MPa or less as determined according to ISO 178:2019 at a temperature of about 23 °C. The yarn has a linear density of from about 1 to about 500 denier per filament and exhibits an elongation at break of about 300% or greater as determined according to ASTM D2653-07 (2018) at a temperature of about 23 °C.

[0005] According to another embodiment of the present disclosure, a method of manufacturing the above multifilament yarn is disclosed. The method includes extruding a melt through a spinneret, the melt including the thermoplastic elastomer composition including the thermoplastic elastomer; withdrawing a first filament and a second filament from the spinneret; and collecting the first filament and the second filament on a take-up roll.

[0006] Other features and aspects of the present disclosure are set forth in greater detail below. BRIEF DESCRIPTION OF DRAWINGS

[0007] The full and achievable disclosures of this specification are set forth in more detail in the remainder of the specification (including reference to the accompanying drawings), in which:

[0008] Figure 1 This is a process schematic diagram of an apparatus that can be used to manufacture filaments according to an embodiment of this disclosure;

[0009] Figure 2A and 2B This is a cross-sectional view of a filament having a double-leaf cross-section according to an embodiment of this disclosure;

[0010] Figure 2C This is a cross-sectional view of a twin-filament multifilament according to another embodiment of this disclosure;

[0011] Figure 3A , 3B 3C is a cross-sectional view of a monofilament having a trilobal cross-section according to another embodiment of this disclosure;

[0012] Figure 4A , 4B 4C is a cross-sectional view of a monofilament having a four-leaf cross-section according to another embodiment of this disclosure;

[0013] Figure 5 This is a cross-sectional view of a three-filament multifilament according to another embodiment of this disclosure;

[0014] Figure 6 This is a cross-sectional view of a four-filament multifilament according to another embodiment of this disclosure;

[0015] Figure 7 A knitting structure according to an embodiment of this disclosure is shown;

[0016] Figure 8 Optical micrographs of the multifilament yarn in Example 1 are provided.

[0017] Reference numerals used repeatedly in this specification and drawings are intended to denote the same or similar features or elements of the invention. Detailed Implementation

[0018] Those skilled in the art will understand that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of this disclosure.

[0019] In general, this disclosure relates to a multifilament yarn based on a thermoplastic elastomer. The inventors of this invention have discovered that by using a thermoplastic elastomer as described herein to form a multifilament yarn having the configuration described herein, filaments and yarns can exhibit desired properties for a variety of applications, particularly textile applications. In particular, articles made from multifilament yarns can be lighter, dry faster, and / or more breathable than those made from other materials. Furthermore, since thermoplastic elastomers can be reshaped upon heating like thermoplastic plastics, yarns and articles formed from thermoplastic elastomers can contribute to a recyclable and circular ecosystem. For example, unlike other types of materials typically used, these materials can be reused and reshaped and therefore may not necessarily require disposal.

[0020] Furthermore, the properties of thermoplastic elastomers and the resulting filaments and yarns allow the use of these materials to overcome certain existing problems. For example, yarns with an elongation greater than 300% can be spun at relatively high speeds to form the resulting articles while minimizing filament and yarn breakage. In addition, the yarns can result in fewer defects during knitting applications (e.g., missed stitches, holes, frayed edges, broken yarns, yarn breakage, inconsistent yarn denier numbers in the fabric, etc.).

[0021] In particular, the yarns disclosed herein may provide tensile strength or elasticity, and are not intended to be theoretically limited, such tensile strength / elasticity can contribute to the usability of the yarn while minimizing yarn breakage. In this regard, the breaking elongation of the yarn may be about 300% or greater, such as about 325% or greater, such as about 350% or greater, such as about 375% or greater, such as about 400% or greater, such as about 450% or greater, such as about 500% or greater, such as about 600% or greater, such as about 800% or greater, such as about 1000% or greater. Elongation at break can be approximately 2000% or less, such as approximately 1800% or less, approximately 1600% or less, approximately 1400% or less, approximately 1200% or less, approximately 1000% or less, approximately 900% or less, approximately 800% or less, approximately 700% or less, approximately 600% or less, approximately 550% or less, approximately 500% or less, approximately 475% or less, approximately 450% or less, approximately 425% or less, approximately 400% or less, or approximately 375% or less. Furthermore, because the yarn can exhibit such a relatively high elongation at break, it is often also referred to as an elastic yarn. Elongation at break can be determined according to ASTM D2653-07 (2018) at a temperature of approximately 23°C.

[0022] In addition to breaking elongation, yarns can also exhibit the desired strength as indicated by toughness. For example, toughness can be about 0.7 g / denier (g / d) or greater, such as about 0.75 g / d or greater, such as about 0.8 g / d or greater, such as about 0.85 g / d or greater, such as about 0.9 g / d or greater, such as about 0.95 g / d or greater, such as about 1 g / d or greater, such as about 1.05 g / d or greater, such as about 1.1 g / d or greater, such as about 1.15 g / d or greater, such as about 1.2 g / d or greater, such as about 1.4 g / d or greater, such as about 1.6 g / d or greater, such as about 1.8 g / d or greater, such as about 2 g / d or greater, such as about 2.5 g / d or greater, such as about 3 g / d or greater, such as about 4 g / d or greater, such as about 5 g / d or greater. Toughness can be approximately 10 g / d or less, such as approximately 8 g / d or less, such as approximately 6 g / d or less, such as approximately 5 g / d or less, such as approximately 4 g / d or less, such as approximately 3.5 g / d or less, such as approximately 3 g / d or less, such as approximately 2.5 g / d or less, such as approximately 2 g / d or less, such as approximately 1.8 g / d or less, such as approximately 1.6 g / d or less, such as approximately 1.4 g / d or less, such as approximately 1.2 g / d or less, such as approximately 1.15 g / d or less, such as approximately 1.1 g / d or less, such as approximately 1.05 g / d or less, such as approximately 1 g / d or less. Toughness can be determined according to ASTM D2653-07 (2017) at a temperature of approximately 23°C.

[0023] Furthermore, even with a relatively high breaking elongation, the yarn can still exhibit a relatively low shrinkage rate. For example, the shrinkage rate can be about 50% or less, such as about 40% or less, about 35% or less, about 30% or less, about 25% or less, about 20% or less, about 15% or less, about 10% or less, about 9% or less, about 8.5% or less, about 8% or less, about 7.5% or less, about 7% or less, about 6.5% or less, about 6% or less, about 5.5% or less, about 5% or less, about 4.5% or less, about 4% or less, about 3.5% or less, about 3% or less, or about 2.5% or less. Shrinkage can be approximately 0% or greater, such as approximately 0.1% or greater, approximately 0.3% or greater, approximately 0.5% or greater, approximately 1% or greater, approximately 1.5% or greater, approximately 2% or greater, approximately 2.5% or greater, approximately 3% or greater, approximately 3.5% or greater, approximately 4% or greater, approximately 4.5% or greater, approximately 5% or greater, approximately 5.5% or greater, approximately 6% or greater, approximately 6.5% or greater, approximately 7% or greater, approximately 7.5% or greater, approximately 10% or greater, approximately 15% or greater, approximately 20% or greater, or approximately 25% or greater. Shrinkage can be determined according to ASTM D2259-02 (2016) (Section 6.6.1, Step 13, Dry heat exposure at approximately 120°C).

[0024] Accordingly, the yarn may have a recoverable elongation of at least about 75%, such as at least about 80%, such as at least about 85%, such as at least about 90%, such as at least about 93%, such as at least about 95%, such as at least about 100%, such as at least about 125%, such as at least about 150%, such as at least about 175%, such as at least about 200%, such as at least about 225%, such as at least about 250%. The recoverable elongation may be about 500% or less, such as about 450% or less, such as about 400% or less, such as about 350% or less, such as about 300% or less, such as about 250% or less, such as about 200% or less, such as about 150% or less, such as about 140% or less, such as about 130% or less, such as about 120% or less, such as about 110% or less, such as about 105% or less, such as about 100% or less. Therefore, when stretched to 1.5 times (150%) of its original length and released, the yarn can quickly and substantially return to its original length. The recoverable elongation can be determined according to ASTM D6720-07 (2018).

[0025] To obtain these beneficial properties, such as relatively high elongation at break and / or relatively low shrinkage, thermoplastic elastomers used in the manufacture of filaments and yarns can also exhibit a certain degree of mechanical strength. In particular, compared to other types of materials, thermoplastic elastomers may be less resistant to bending deformation, and therefore may exhibit a relatively low flexural modulus. For example, the flexural modulus can be about 300 MPa or less, such as about 260 MPa or less, such as about 220 MPa or less, such as about 200 MPa or less, such as about 190 MPa or less, such as about 180 MPa or less, such as about 170 MPa or less, such as about 160 MPa or less, such as about 150 MPa or less, such as about 140 MPa or less, such as about 130 MPa or less, such as about 120 MPa or less, such as about 110 MPa or less, such as about 100 MPa or less, such as about 90 MPa or less, such as about 80 MPa or less, such as about 70 MPa or less, such as about 60 MPa or less, such as about 50 MPa or less, such as about 40 MPa or less, such as about 30 MPa or less, such as about 20 MPa or less. The flexural modulus can be about 10 MPa or greater, such as about 15 MPa or greater, such as about 20 MPa or greater, such as about 25 MPa or greater, such as about 30 MPa or greater, such as about 35 MPa or greater, such as about 40 MPa or greater, such as about 45 MPa or greater, such as about 50 MPa or greater, such as about 60 MPa or greater, such as about 70 MPa or greater, such as about 80 MPa or greater, such as about 90 MPa or greater, such as about 100 MPa or greater, such as about 110 MPa or greater, such as about 120 MPa or greater, such as about 130 MPa or greater, such as about 140 MPa or greater, such as about 150 MPa or greater, such as about 180 MPa or greater, or about 200 MPa or greater. The flexural modulus can be determined according to ISO 178:2019 at a temperature of about 23°C.

[0026] Accordingly, thermoplastic elastomers can have a specific Shore D hardness, which provides an indication of the elastomer's resistance to indentation. In this regard, the Shore D hardness can be about 15 or greater, such as about 20 or greater, such as about 25 or greater, such as about 30 or greater, such as about 35 or greater, such as about 40 or greater, such as about 45 or greater, such as about 50 or greater. The Shore D hardness can also be about 60 or less, such as about 55 or less, such as about 50 or less, such as about 45 or less, such as about 40 or less, such as about 35 or less, such as about 30 or less. This hardness allows the thermoplastic elastomer to provide the compliance required for effective use in filaments / yarns and resulting articles. The Shore D hardness can be determined according to ISO 868-2003 (15 seconds).

[0027] In addition, thermoplastic elastomers can possess other beneficial mechanical properties. For example, the tensile stress at break can be about 45 MPa or less, such as about 40 MPa or less, such as about 35 MPa or less, such as about 30 MPa or less, such as about 30 MPa or less, such as about 25 MPa or less. The tensile stress at break can be about 5 MPa or greater, such as about 10 MPa or greater, such as about 15 MPa or greater, such as about 20 MPa or greater, such as about 25 MPa or greater, such as about 30 MPa or greater, such as about 35 MPa or greater. The tensile stress at break can be determined according to ISO 527-1 / -2 (2012) at a temperature of about 23°C.

[0028] In addition, thermoplastic elastomers can have relatively high nominal strain at break. For example, the nominal strain at break can be about 200% or greater, such as about 250% or greater, such as about 300% or greater, such as about 350% or greater, such as about 400% or greater, such as about 450% or greater, such as about 500% or greater, such as about 550% or greater, such as about 600% or greater, such as about 650% or greater, such as about 700% or greater, such as about 750% or greater, such as about 800% or greater, such as about 850% or greater. The nominal strain at break can be about 2000% or less, such as about 1800% or less, about 1600% or less, about 1400% or less, about 1200% or less, about 1100% or less, about 1000% or less, about 950% or less, about 900% or less, about 850% or less, about 800% or less, about 700% or less, about 600% or less, or about 500% or less. The nominal strain at break can be determined according to ISO 527-1 / -2 (2012) at a temperature of about 23°C.

[0029] Various embodiments disclosed herein will now be described in more detail. I. Thermoplastic Elastomer Composition

[0030] Typically, yarns as disclosed herein are formed from one or more thermoplastic elastomers. In this regard, one or more thermoplastic elastomers may be present in a thermoplastic elastomer composition comprising one or more thermoplastic elastomers and optionally one or more additives as defined herein and / or commonly known in the art. However, it should be understood that in some embodiments, one or more thermoplastic elastomers may constitute the entirety of the composition (e.g., without the addition of one or more additives). A. Thermoplastic Elastomer

[0031] As noted above, the thermoplastic elastomer composition comprises one or more thermoplastic elastomers. The thermoplastic elastomer can be a thermoplastic elastomer as defined in ISO 18064:2003(E). For example, the thermoplastic elastomer can be a thermoplastic polyolefin elastomer (TPO), a thermoplastic styrene elastomer (TPS), a thermoplastic polyether or polyester polyurethane (TPU), a thermoplastic polyamide block copolymer (TPA), a thermoplastic polyester elastomer (TPC), or a mixture thereof. In one specific embodiment, one or more thermoplastic elastomers may include thermoplastic polyester elastomers, particularly thermoplastic copolyester elastomers, such as thermoplastic copolyether ester elastomers and / or thermoplastic copolyester ester elastomers.

[0032] In one embodiment, the thermoplastic elastomer may be a thermoplastic polyolefin elastomer. Typically, thermoplastic polyolefin elastomers comprise thermoplastic olefin polymers (e.g., polypropylene or polyethylene) blended with thermosetting elastomers. For example, typical thermoplastic polyolefin elastomers may include melt blends or reactor blends of polyolefins and olefin copolymer elastomers. The polyolefin may be polyethylene or polypropylene, preferably polypropylene. The olefin copolymer elastomer may be an ethylene copolymer. For example, an ethylene copolymer may contain ethylene and another olefin monomer, particularly an α-olefin monomer. For example, an ethylene copolymer may include ethylene-propylene copolymers, ethylene-butene copolymers, ethylene-hexene copolymers, ethylene-octene copolymers, and / or ethylene-butadiene copolymers. In particular, the copolymer may be an ethylene-propylene copolymer, especially an ethylene-propylene-diene copolymer.

[0033] In one embodiment, the thermoplastic elastomer may be a thermoplastic styrene elastomer. Typically, thermoplastic styrene elastomers comprise block copolymers of polystyrene and rubbery polymeric materials. The rubbery polymeric materials may include, but are not limited to, polybutadiene, hydrogenated polybutadiene, mixtures of polybutadiene, poly(ethylene-propylene), and / or hydrogenated polyisoprene. Specific block copolymers of the styrene / conjugated diene / styrene type include SBS, SIS, SIBS, SEBS, and SEPS block copolymers.

[0034] In one embodiment, the thermoplastic elastomer may be a thermoplastic polyurethane. Typically, thermoplastic polyurethanes comprise linear segment block copolymers consisting of hard segments comprising diisocyanates and short-chain diols and soft segments comprising diisocyanates and long-chain polyols, as represented by the following general formula: in "X" indicates a hard segment containing diisocyanate and short-chain diol. "Z" indicates a soft segment containing diisocyanate and long-chain polyol, and “Y” represents the diisocyanate residue in the urethane bond that connects the X and Z segments. Long-chain polyols can include those of the polyether type, such as poly(alkylene oxide) glycol, or those of the polyester type.

[0035] In one embodiment, the thermoplastic elastomer may be a thermoplastic polyamide block copolymer. Typically, thermoplastic polyamide block copolymers comprise linear and regular chains of polyamide segments and flexible polyether or polyester segments, or soft segments having both ether and ester bonds, as represented by the following general formula: in “PA” represents a linear saturated aliphatic polyamide sequence. "PE" represents a polyoxyethylene sequence formed from linear or branched aliphatic polyoxyethylene glycols or long-chain polyols having ether bonds, ester bonds, or both types of bonds, or mixtures thereof, or from coethers and copolyesters derived therefrom. n is an integer greater than 1. The softness of co-ether amide block copolymers or copolyester amide block copolymers generally decreases with increasing relative amount of polyamide units.

[0036] In one embodiment, the thermoplastic elastomer may be a thermoplastic polyester elastomer. The thermoplastic polyester elastomer may be a thermoplastic copolyester elastomer, such as a thermoplastic copolyether ester elastomer and / or a thermoplastic copolyester ester elastomer. In one embodiment, the thermoplastic polyester elastomer may be a thermoplastic copolyester ester elastomer. In a specific embodiment, the thermoplastic polyester elastomer may be a thermoplastic copolyether ester elastomer.

[0037] As noted above, thermoplastic polyester elastomers can be copolyester elastomers. Typically, copolyester elastomers are block copolymers containing (a) hard polyester segments and (b) soft polyester segments. Examples of hard polyester segments include, but are not limited to, polyalkylene terephthalate, poly(cyclohexanedicarboxylate), etc. Examples of soft polyester segments include, but are not limited to, aliphatic polyesters, including, but not limited to, polybutylene adipate, tetramethyl adipate, and polycaprolactone, etc.

[0038] Copolyester elastomers may contain one or more ester unit blocks of a high-melting-point polyester and one or more ester unit blocks of a low-melting-point polyester, these blocks being linked together by ester groups or urethane groups. Copolyester elastomers containing urethane groups can be prepared by reacting different polyesters in a molten phase, followed by reacting the resulting copolyester with a low molecular weight polyisocyanate. The polyisocyanate may be a diisocyanate or a triisocyanate. Specifically, the polyisocyanate may be a diisocyanate, such as p-toluene diisocyanate, diphenylmethane diisocyanate, phenyl diisocyanate, hexamethylene diisocyanate, and / or isophorone diisocyanate.

[0039] As noted above, thermoplastic polyester elastomers can be coether ester elastomers. Typically, coether ester elastomers can have multiple repeating long-chain ester units and short-chain ester units linked head-to-tail by ester bonds. The long-chain ester unit can be represented by formula (A): Furthermore, the short-chain ester unit can be represented by formula (B): in G is the divalent group remaining after removing the terminal hydroxyl groups from a long-chain polymeric diol having a number average molecular weight between about 400 and about 6000, preferably between about 400 and about 3000, and even more preferably between about 600 and about 3000. R is the divalent group remaining after removing the carboxyl group from a dicarboxylic acid having a number average molecular weight of less than about 300; and D is the divalent group remaining after removing the hydroxyl group from a diol having a number-average molecular weight of less than about 250.

[0040] As used herein, the term "long-chain ester unit" refers to the reaction product of a long-chain diol and a dicarboxylic acid. Long-chain diols are polymeric diols having terminal (or as close to terminal) hydroxyl groups. In particular, suitable long-chain diols include poly(alkyleneoxy)diols having terminal (or as close to terminal) hydroxyl groups and having a number average molecular weight from about 400 to about 6000, from about 400 to about 3000, from about 600 to about 3000, from about 1000 to about 3000, or from about 1000 to about 2000. Furthermore, long-chain diols may have a melting point of less than about 65°C, from less than about 60°C, from less than about 55°C, or from less than about 50°C. Long-chain diols are typically diol esters of poly(alkyleneoxy)diols or poly(alkyleneoxy)dicarboxylic acids. Preferred poly(alkyleneoxy) glycols include poly(tetramethyleneoxy) glycol, poly(trimethyleneoxy) glycol, poly(propyleneoxy) glycol (e.g., 1,2- or 1,3-propyleneoxy), poly(ethyleneoxy) glycol, poly(hexamethyleneoxy) glycol, poly(heptamethyleneoxy) glycol, poly(octamethyleneoxy) glycol, poly(nonamethyleneoxy) glycol, and poly(1,2-butyloxy) glycol, copolymer glycols of these epoxides, and block copolymers such as ethylene oxide-terminated poly(propyleneoxy) glycols. Furthermore, it should be understood that mixtures of two or more of these glycols may also be used. Additionally, any substituents that do not interfere with the polymerization of the compound with one or more glycols or one or more dicarboxylic acids (as the case may be) are permitted. The hydroxyl functional groups of the long-chain glycols that react to form the copolyester may, to a feasible extent, be terminal groups. The terminal hydroxyl group can be placed on a terminal diol unit that is different from the chain (e.g., an ethylene oxide terminal group on poly(propylene oxide diol)). The long-chain ester unit having formula (A) can also be referred to as the "soft segment" of the copolyether ester elastomer.

[0041] As used herein, the term "short-chain ester unit" refers to a low molecular weight compound or polymer chain unit having a number average molecular weight of less than about 550, such as less than about 525, such as less than about 500, such as less than about 475, such as less than about 450. They are typically prepared by reacting a low molecular weight diol or mixture of diols (with a molecular weight less than about 250, such as less than about 225, such as less than about 200, such as less than about 175, such as less than about 150) with a dicarboxylic acid to form an ester unit represented by formula (B) above. Short-chain ester units having formula (B) can also be referred to as "hard segments" of copolyether ester polymers.

[0042] The low molecular weight diols that form the short-chain ester units used to prepare copolyesters include acyclic, alicyclic, and aromatic dihydroxy compounds. These compounds include diols having about 2 to about 15 carbon atoms, such as about 2 to about 8 carbon atoms, or about 2 to about 6 carbon atoms, such as ethylene glycol, propylene glycol, isobutylene glycol, tetramethylene glycol, 1,4-pentamethylene glycol, 2,2-dimethyltrimethylene glycol, hexamethylene glycol, and decamethylene glycol, dihydroxycyclohexane, cyclohexanediol, resorcinol, hydroquinone, 1,5-dihydroxynaphthalene, etc. In particular, the diol can be an aliphatic diol, such as 1,4-butanediol, ethylene glycol, 1,3-propanediol, cyclohexanediol, and / or hexamethylene glycol. For example, the diol can be ethylene glycol, 1,4-butanediol, 1,3-propanediol, or combinations thereof. Specifically, the diol may be 1,4-butanediol, 1,3-propanediol, or a combination thereof. In one embodiment, 1,4-butanediol is preferred. In another embodiment, ethylene glycol is preferred. In yet another further embodiment, 1,3-propanediol is preferred. In one embodiment, 1,4-butanediol may be provided as a mixture with ethylene glycol, 1,3-propanediol, cyclohexanediol, and / or hexamethylenediol. Among the bisphenols that may be used are bis(p-hydroxy)biphenyl, bis(p-hydroxyphenyl)methane, and bis(p-hydroxyphenyl)propane. Equivalent ester-forming derivatives of the diol are also useful (e.g., ethylene oxide or ethylene carbonate may be used instead of ethylene glycol, or resorcinol diacetate may be used instead of resorcinol).

[0043] As used herein, the term "diol" includes equivalent ester-forming derivatives, such as those mentioned. However, the molecular weight requirement refers to the corresponding diol, not its derivatives.

[0044] Dicarboxylic acids that can react with the aforementioned long-chain diols and low-molecular-weight diols to produce copolyether esters can include aliphatic, cyclic aliphatic, or aromatic dicarboxylic acids with low molecular weights (e.g., having a molecular weight of less than about 300, such as less than about 275, such as less than about 250, such as less than about 225). As used herein, the term "dicarboxylic acid" includes functional equivalents of dicarboxylic acids having two carboxyl functional groups, which behave substantially similarly to dicarboxylic acids in the formation of thermoplastic copolyether ester elastomers in reactions with diols and diols. These equivalents include esters as well as ester-forming derivatives such as acyl halides and acid anhydrides. The molecular weight requirement pertains to acids rather than their equivalent esters or ester-forming derivatives.

[0045] Therefore, esters of dicarboxylic acids having a molecular weight greater than 300, or functional equivalents of dicarboxylic acids having a molecular weight greater than 300, are also suitable, provided that the corresponding acid has a molecular weight less than about 300 or the aforementioned molecular weight. The dicarboxylic acid may contain any substituents or combinations that substantially do not interfere with the formation of the thermoplastic coether ester elastomer and the use of the thermoplastic coether ester elastomer in the composition.

[0046] As used herein, the term "aliphatic dicarboxylic acid" refers to a carboxylic acid having two carboxyl groups, each attached to a saturated carbon atom. If the carbon atom to which the carboxyl group is attached is saturated and is in a ring, the acid is cyclic aliphatic. Aliphatic or cyclic aliphatic acids with conjugated unsaturation are generally unusable due to homopolymerization. However, some unsaturated acids, such as maleic acid, can be used.

[0047] As used herein, the term "aromatic dicarboxylic acid" refers to a dicarboxylic acid having two carboxyl groups, each attached to a carbon atom in an aromatic ring structure. The two carboxyl functional groups do not necessarily have to be attached to the same aromatic ring, and in the presence of more than one ring, they can be linked by aliphatic or aromatic divalent groups or divalent groups such as -O- or -SO2-.

[0048] Representative aliphatic and cycloaliphatic acids that may be used include, but are not limited to, sebacic acid; 1,3-cyclohexanedicarboxylic acid; 1,4-cyclohexanedicarboxylic acid; adipic acid; glutaric acid; succinic acid; 4-cyclohexane-1,2-dicarboxylic acid; 2-ethyloctanoic acid; cyclopentanedicarboxylic acid; decahydro-1,5-naphthalenedicarboxylic acid; 4,4′-dicyclohexyldicarboxylic acid; decahydro-2,6-naphthalenedicarboxylic acid; 4,4′-methylenebis(cyclohexyl)carboxylic acid; 3,4-furandicarboxylic acid; and mixtures thereof. In one embodiment, preferred acids may include cyclohexanedicarboxylic acid and / or adipic acid.

[0049] Representative aromatic dicarboxylic acids that can be used include, but are not limited to, phthalic acid, terephthalic acid, and isophthalic acid; biphenyl acid; substituted dicarboxylic acid compounds having two benzene rings, such as bis(p-carboxyphenyl)methane; p-oxy-1,5-naphthalenedicarboxylic acid; 2,6-naphthalenedicarboxylic acid; 2,7-naphthalenedicarboxylic acid; 4,4′-sulfonyl dibenzoic acid and its C1-C1 derivatives. 12 Alkyl and cyclic substituted derivatives, such as halogenated, alkoxylated, and aryl derivatives; and mixtures thereof. Hydroxy acids such as p-(β-hydroxyethoxy)benzoic acid may also be used, provided that an aromatic dicarboxylic acid is also used.

[0050] In one embodiment, aromatic dicarboxylic acids are preferably used to prepare thermoplastic coether ester elastomers. Among aromatic dicarboxylic acids, those having 8 to 16 carbon atoms, such as 8 to 12 carbon atoms, or such as 8 to 10 carbon atoms, are preferred. In particular, aromatic dicarboxylic acids may include terephthalic acid, phthalic acid, and / or isophthalic acid. Specifically, aromatic dicarboxylic acids may include terephthalic acid, isophthalic acid, or combinations thereof. In one embodiment, the aromatic acid may include terephthalic acid alone or terephthalic acid mixed with phthalic acid and / or isophthalic acid.

[0051] In one embodiment, when a mixture of two or more dicarboxylic acids is used to prepare the copolyether ester, isophthalic acid may be the preferred second dicarboxylic acid. For example, isophthalic acid may be provided as a mixture with terephthalic acid. In this respect, the amount of copolyisophthalate residues in the copolyether ester may be less than 35 mol%, such as less than 30 mol%, such as less than 25 mol%. Similarly, based on the total weight of the copolydicarboxylic acid residues -(-C(O)RC(O)-)- in the copolyether ester, the amount of copolyisophthalate residues in the copolyether ester may be less than 35 wt.%, such as less than 30 wt.%, such as less than 25 wt.%. Based on the total number of moles of the copolydicarboxylic acid residues -(-C(O)RC(O)-)- in the copolyether ester, the remaining phenylene digroups may be derived from terephthalic acid.

[0052] Furthermore, in one embodiment, at least about 70 mol.% of the group represented by R in formulas (A) and (B) above may be 1,4-phenylene, and at least about 70 mol.% of the group represented by D in formula (B) above may be 1,4-butylene, and the sum of the percentages of R groups that are not 1,4-phenylene and D groups that are not 1,4-butylene may not exceed 30 mol.%.

[0053] For example, the coether ester may have a hard segment composed of polybutylene terephthalate and a soft segment composed of about 5 wt.% to about 80 wt.%, such as about 5 wt.% to about 75 wt.%, such as about 10 wt.% to about 70 wt.%, such as about 10 wt.% to about 60 wt.%, such as about 20 wt.% to about 60 wt.%. The polyether block may be derived from polytetramethylene glycol. Complementarily, the fraction of the hard segment may be about 20 wt.% to about 95 wt.%, such as about 20 wt.% to about 90 wt.%, such as about 30 wt.% to about 90 wt.%, such as about 40 wt.% to about 90 wt.%, such as about 40 wt.% to about 80 wt.%.

[0054] While not limited, preferred thermoplastic coether ester elastomers include those prepared from monomers comprising: (A) (1) poly(tetramethyleneoxy) glycol, (2) a dicarboxylic acid selected from isophthalic acid, terephthalic acid, or mixtures thereof, and (3) a diol selected from 1,4-butanediol, 1,3-propanediol, or mixtures thereof; (B) (1) poly(trimethyleneoxy) glycol, (2) a dicarboxylic acid selected from isophthalic acid, terephthalic acid, or mixtures thereof, and (3) a diol selected from 1,4-butanediol, 1,3-propanediol, or mixtures thereof; or (C) (1) ethylene oxide-terminated poly(propyleneoxy) glycol; (2) a dicarboxylic acid selected from isophthalic acid, terephthalic acid, or mixtures thereof; and (3) a diol selected from 1,4-butanediol, 1,3-propanediol, or mixtures thereof.

[0055] Preferably, the thermoplastic coether ester elastomer can be prepared from esters or mixtures of terephthalic acid or isophthalic acid, 1,4-butanediol and poly(tetramethylene ether) glycol, poly(trimethylene ether) glycol or ethylene oxide-terminated polypropylene glycol, or it can be prepared from esters of terephthalic acid (e.g., dimethyl terephthalate), 1,4-butanediol and poly(ethylene ether) glycol. More preferably, the thermoplastic coether ester elastomer can be prepared from esters of terephthalic acid (e.g., dimethyl terephthalate), 1,4-butanediol and poly(tetramethylene ether) glycol.

[0056] For example, in one specific embodiment, the thermoplastic coether ester elastomer may have the following formula: -[4GT] x -[BT] y - where 4G is a residue of butanediol (such as 1,4-butanediol), B is a residue of poly(tetramethylene ether glycol) and T is terephthalate, and where x is from about 0.60 to about 0.99 and y is from about 0.01 to about 0.40.

[0057] On the one hand, the thermoplastic coether ester elastomer can be a block copolymer of polybutylene terephthalate and polyether segments, and can have the following structure: Where a and b are integers and can vary from 2 to 10,000. The ratio between hard and soft segments in the block copolymer as described above can be varied to alter the properties of the elastomer.

[0058] Typically, thermoplastic coether ester elastomers preferably contain about 1 wt.% or more, such as about 5 wt.% or more, such as about 10 wt.% or more, such as about 20 wt.% or more, such as about 25 wt.% or more, such as about 30 wt.% or more, such as about 35 wt.% or more, such as about 40 wt.% or more, such as about 45 wt.% or more, such as about 50 wt.% or more, such as about 55 wt.% or more, and copolymer residues corresponding to the long-chain ester unit (hard segment) of formula (A) above. Thermoplastic coether ester elastomers preferably contain about 85 wt.% or less, such as about 80 wt.% or less, such as about 75 wt.% or less, such as about 70 wt.% or less, such as about 65 wt.% or less, such as about 60 wt.% or less, and copolymer residues corresponding to the long-chain ester unit (hard segment) of formula (A) above.

[0059] Typically, thermoplastic copolyether ester elastomers preferably contain about 10 wt.% or more, such as about 20 wt.% or more, such as about 25 wt.% or more, such as about 30 wt.% or more, such as about 35 wt.% or more, such as about 40 wt.% or more, such as about 45 wt.% or more, such as about 50 wt.% or more of copolymer residues corresponding to short-chain ester units (soft segments) of formula (B) above. The thermoplastic copolyether ester elastomer preferably contains about 99 wt.% or less, such as about 95 wt.% or less, such as about 90 wt.% or less, such as about 85 wt.% or less, such as about 80 wt.% or less, such as about 75 wt.% or less, such as about 70 wt.% or less, such as about 65 wt.% or less, such as about 60 wt.% or less, such as about 55 wt.% or less of the short-chain ester unit (soft segment) corresponding to formula (B) above.

[0060] In one embodiment, the thermoplastic copolyether ester elastomer may contain only copolymer residues of long-chain ester units corresponding to formula (A) and short-chain ester units corresponding to formula (B). In this respect, the weight percentages of the copolyether ester having formulas (A) and (B) can be complementary. That is, the sum of the weight percentages of the copolyether units having formulas (A) and (B) can be 100 wt.%. Similarly, the molar percentages of R groups in the copolyether ester copolymer having formulas (A) and (B) can be complementary. That is, the sum of the molar percentages of R groups in the copolyether units having formulas (A) and (B) can be 100 mol.%.

[0061] Furthermore, it should be understood that mixtures of two or more thermoplastic elastomers, particularly thermoplastic copolyether ester elastomers, can be used. In one embodiment, the composition may contain one thermoplastic elastomer as defined herein. In other embodiments, the composition may comprise a mixture of thermoplastic elastomers. For example, more than one thermoplastic elastomer, such as two or three thermoplastic elastomers, may be used in the composition.

[0062] Specifically, regarding thermoplastic polyester elastomers, particularly mixtures of thermoplastic coether ester elastomers, each elastomer used individually need not fall within the values ​​described above for the elastomers. However, in this respect, mixtures of two or more thermoplastic coether ester elastomers may conform to the values ​​described herein for coether esters on a weighted average basis. For example, in a mixture containing equal amounts of two thermoplastic coether ester elastomers, for a weighted average of 45 weight percent of short-chain ester units, one thermoplastic coether ester elastomer may contain 60 weight percent of short-chain ester units, and the other resin may contain 30 weight percent of short-chain ester units.

[0063] Regarding the properties of thermoplastic elastomers, it may be desirable to have melt flow that allows the thermoplastic elastomer to be processed in a relatively easy manner to form filaments and yarns as disclosed herein. In this regard, thermoplastic elastomers can exhibit relatively low melt viscosity, as indicated by the melt flow rate. For example, the melt flow rate of a thermoplastic elastomer can be about 0.5 g / 10 min or greater, such as about 1 g / 10 min or greater, such as about 2 g / 10 min or greater, such as about 3 g / 10 min or greater, such as about 4 g / 10 min or greater, such as about 5 g / 10 min or greater, such as about 8 g / 10 min or greater, such as about 10 g / 10 min or greater, such as about 15 g / 10 min or greater. The melt flow rate can be about 40 g / 10 min or less, such as about 35 g / 10 min or less, such as about 30 g / 10 min or less, such as about 25 g / 10 min or less, such as about 20 g / 10 min or less, such as about 15 g / 10 min or less, such as about 10 g / 10 min or less, such as about 8 g / 10 min or less, such as about 6 g / 10 min or less, such as about 5 g / 10 min or less, such as about 4 g / 10 min or less, such as about 3 g / 10 min or less. The melt flow rate can be determined according to ISO 1133 at 220°C under a 2.16 kg load.

[0064] Thermoplastic elastomers can also have relatively low melt temperatures. For example, the melt temperature can be about 100°C or higher, such as about 110°C or higher, such as about 130°C or higher, such as about 150°C or higher, such as about 170°C or higher, such as about 190°C or higher, such as about 200°C or higher, such as about 220°C or higher, such as about 240°C or higher. The melt temperature can also be about 300°C or lower, such as about 280°C or lower, such as about 250°C or lower, such as about 230°C or lower, such as about 210°C or lower, such as about 200°C or lower, such as about 180°C or lower, such as about 160°C or lower, such as about 140°C or lower, such as about 120°C or lower. The melting temperature can be determined using methods known in the art, such as differential scanning calorimetry at a rate of 10°C / min according to ISO 11357-1:2023.

[0065] Furthermore, the glass transition temperature of thermoplastic elastomers, particularly thermoplastic copolyester elastomers, can be within a specific range. For example, the glass transition temperature can be about -80°C or higher, such as about -70°C or higher, such as about -60°C or higher, such as about -50°C or higher, such as about -40°C or higher, such as about -30°C or higher. The glass transition temperature can also be about 0°C or lower, such as about -5°C or lower, such as about -10°C or lower, such as about -20°C or lower, such as about -30°C or lower, such as about -40°C or lower. Additionally, the glass transition temperature of the hard segments of thermoplastic copolyester elastomers can also be within a specific range. For example, the glass transition temperature of the hard segment can be about 30°C or higher, such as about 35°C or higher, such as about 40°C or higher, such as about 45°C or higher, such as about 50°C or higher, such as about 55°C or higher, such as about 60°C or higher, such as about 65°C or higher, such as about 70°C or higher, such as about 75°C or higher, such as about 80°C or higher. The glass transition temperature can be about 150°C or lower, such as about 140°C or lower, such as about 130°C or lower, such as about 120°C or lower, such as about 110°C or lower, such as about 100°C or lower, such as about 90°C or lower, such as about 80°C or lower, such as about 70°C or lower, such as about 60°C or lower, such as about 55°C or lower, such as about 50°C or lower, such as about 45°C or lower, such as about 40°C or lower, such as about 35°C or lower, such as about 30°C or lower. The glass transition temperature can be determined using methods known in the art, such as differential scanning calorimetry at a rate of 10°C / min according to ISO 11357-1:2023.

[0066] Furthermore, thermoplastic elastomers can have specific densities. For example, a density of approximately 1 g / cm³. 3Or larger, such as approximately 1.03 g / cm³ 3 Or larger, such as approximately 1.05 g / cm³ 3 Or larger, such as approximately 1.08 g / cm³ 3 Or larger, such as about 1.1 g / cm³ 3 Or larger, such as approximately 1.15 g / cm³ 3 Or larger, such as approximately 1.2 g / cm³ 3 Or larger, such as approximately 1.3 g / cm³ 3 Or even larger. Thermoplastic elastomers can have approximately 2 g / cm³. 3 Or smaller, such as about 1.8 g / cm³ 3 Or smaller, such as about 1.6 g / cm³ 3 Or smaller, such as about 1.4 g / cm³ 3 Or smaller, such as about 1.3 g / cm³ 3 Or smaller, such as about 1.25 g / cm³ 3 Or smaller, such as about 1.2 g / cm³ 3 Or smaller, such as about 1.18 g / cm³ 3 Or smaller, such as about 1.15 g / cm³ 3 Or smaller, such as about 1.12 g / cm³ 3 Or smaller, such as about 1.1 g / cm³ 3 Or even lower density. Density can be determined according to ISO 1183-1:2019.

[0067] Thermoplastic elastomer compositions typically contain one or more thermoplastic elastomers in amounts of about 10 wt.% or more, such as about 15 wt.% or more, such as about 20 wt.% or more, such as about 25 wt.% or more, such as about 30 wt.% or more, such as about 35 wt.% or more, such as about 40 wt.% or more, such as about 50 wt.% or more, such as about 60 wt.% or more, such as about 70 wt.% or more, such as about 80 wt.% or more, such as about 90 wt.% or more, such as about 95 wt.% or less, such as about 100 wt.% or less, such as about 95 wt.% or less, such as about 90 wt.% or less, such as about 80 wt.% or less, such as about 70 wt.% or less, such as about 60 wt.% or less, such as about 50 wt.% or less. B. Additives

[0068] In addition to the thermoplastic elastomer, the thermoplastic elastomer composition may optionally further comprise one or more additives. In this regard, in one embodiment, the thermoplastic copolyester elastomer composition may further comprise one or more additives. For example, the additives may include those typically used in the art to provide a resulting material having the desired properties. These additives may include, but are not limited to, fillers, reinforcing agents, processing aids, plasticizers, stabilizers (e.g., heat stabilizers; UV light stabilizers; metal deactivators; antioxidants, such as phenols, phosphites and / or amine-containing antioxidants; etc.), viscosity modifiers, nucleating agents, lubricants, flow-enhancing additives, flame retardants (e.g., phosphates, such as polyphosphates, pyrophosphates, etc.; phosphinates; etc.), impact modifiers, antistatic agents, antimicrobial agents, colorants, pigments, etc.

[0069] When used, the corresponding additive may be present in the thermoplastic elastomer composition in amounts of about 0.01 wt.% or more, such as about 0.05 wt.% or more, such as about 0.1 wt.% or more, such as about 0.2 wt.% or more, such as about 0.3 wt.% or more, such as about 0.5 wt.% or more, such as about 0.8 wt.% or more, such as about 1 wt.% or more, such as about 1.5 wt.% or more, such as about 2 wt.% or more, such as about 2.5 wt.% or more, such as about 3 wt.% or more, such as about 5 wt.% or more, based on the weight of the thermoplastic elastomer composition. The corresponding additives may be present in the thermoplastic elastomer composition in amounts of about 20 wt.% or less, such as about 15 wt.% or less, such as about 12 wt.% or less, such as about 10 wt.% or less, such as about 8 wt.% or less, such as about 6 wt.% or less, such as about 5 wt.% or less, such as about 4 wt.% or less, such as about 3 wt.% or less, such as about 2.8 wt.% or less, such as about 2.5 wt.% or less, such as about 2.3 wt.% or less, such as about 2 wt.% or less, such as about 1.8 wt.% or less, such as about 1.6 wt.% or less, such as about 1.4 wt.% or less, such as about 1.2 wt.% or less, such as about 1 wt.% or less, such as about 0.8 wt.% or less, such as about 0.5 wt.% or less, based on the weight of the thermoplastic elastomer composition. In another embodiment, the above weight percentage may be based on the weight of one or more thermoplastic elastomers.

[0070] In one embodiment, the thermoplastic elastomer composition may comprise one or more non-elastomeric polymers. Generally, any non-elastomeric polymer can be used. For example, the non-elastomeric polymer may be a thermoplastic polymer, a thermosetting polymer, or a mixture thereof. In one embodiment, the non-elastomeric polymer may be a thermoplastic polymer. In another embodiment, the non-elastomeric polymer may be a thermosetting polymer.

[0071] In this regard, non-elastomeric polymers may include, but are not limited to, poly(meth)acrylic acid, polyacrylate, polystyrene, polyolefins (e.g., polyethylene, such as high-density polyethylene, low-density polyethylene, linear low-density polyethylene, ultra-low-density polyethylene; polypropylene, etc.), polyurethane, polyurea, epoxy resins, polyesters (e.g., poly(ethylene terephthalate), poly(1,3-propyl terephthalate), poly(1,4-butanediol terephthalate), PETG, poly(ethylene glycol terephthalate-co-1,4-cyclohexanediol)), alkyd resins, and polyamides (e.g., nylon, nylon 6, nylon 46, nylon 6...). 6. Nylon 612), polyamide-imide, polyvinyl alcohol, phenoxy resin, amino resin, melamine, polyether, polyvinyl alcohol acetal, polyvinyl alcohol formaldehyde, poly(vinyl butyrate), polyacetylene, polyether, silicone resin, ABS resin, polysulfone, polyamine sulfone, polyethersulfone, polyphenylene sulfone, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyvinyl alcohol, polyvinyl carbazole, butyral, polyphenylene ether, polypyrrole, poly(terephthalamide), cellulose derivatives, polytetrafluoroethylene, polytrifluoroethylene, polyvinylidene fluoride, phenolic varnish, poly(cresol), polycarbonate, polysulfides, poly(phenylene sulfide), poly(2,6-dimethylphenylene ether), etc. It should be understood that such non-elastomeric polymers may also include modified forms of any of the foregoing substances and their copolymers. Furthermore, it should be understood that the composition may contain a combination of two or more of the foregoing substances. In one embodiment, one or more non-elastomeric polymers may be miscible with thermoplastic elastomer copolymers and / or thermoplastic elastomer polymer compositions.

[0072] When one or more non-elastomeric polymers are present in a thermoplastic elastomer composition, they can be present in any amount. However, in one embodiment, they can be present in amounts less than that of the thermoplastic elastomer.

[0073] One or more non-elastomeric polymers may be present in the thermoplastic elastomer composition in amounts based on the total weight of the thermoplastic elastomer composition, such as about 1 wt.% or more, such as about 2 wt.% or more, such as about 5 wt.% or more, such as about 10 wt.% or more, such as about 15 wt.% or more, such as about 20 wt.% or more, such as about 25 wt.% or more, such as about 30 wt.% or more, such as about 35 wt.% or more, such as about 40 wt.% or more. One or more non-elastomeric polymers may be present in amounts of about 60 wt.% or less, such as about 50 wt.% or less, such as about 40 wt.% or less, such as about 35 wt.% or less, such as about 30 wt.% or less, such as about 25 wt.% or less, such as about 20 wt.% or less, such as about 15 wt.% or less, such as about 10 wt.% or less, such as about 8 wt.% or less, such as about 5 wt.% or less, based on the total weight of the thermoplastic elastomer composition. C. Composition Formation

[0074] The thermoplastic elastomer compositions described herein can be processed using techniques generally known in the art. For example, the components (thermoplastic elastomer and optional additives) can be melt-blended (also known as melt blending). Using such a method, these components can be sufficiently dispersed throughout the composition. Furthermore, these components can be added in a single step or provided in a stepwise manner. Processing can be carried out in a chamber, which can be any container suitable for blending the composition under the necessary temperature and shear force conditions. In this regard, the chamber can be a mixer, such as a Banbury™ mixer or a Brabender™ mixer, an extruder, such as a co-rotating extruder, a counter-rotating extruder, or a twin-screw extruder, a co-kneader, such as a Buss® kneader, etc. After mixing / blending, the composition can be milled, shredded, extruded, granulated, or processed by any other desired technique. In some cases, these components can be melt-blended and fed directly to downstream operations, such as spinnerets for forming filaments and yarns as disclosed herein. In particular, once formed, the thermoplastic elastomer composition can be used to form filaments and yarns as further described herein. II. Filaments and Yarns

[0075] As noted herein, thermoplastic elastomer compositions are suitable for forming filaments and corresponding yarns. While thermoplastic elastomer compositions can be used to form staple fiber yarns, in one specific embodiment, they are used to form continuous filaments and corresponding yarns. In particular, the properties of thermoplastic elastomers allow them to be processed at the speeds and conditions disclosed herein to form filaments, and subsequently to be processed into yarns and resulting articles.

[0076] The filaments disclosed herein can be manufactured using conventional methods known in the art. For example, these methods may include general steps such as spinning and optionally drawing a thermoplastic elastomer composition (containing a thermoplastic elastomer) into filaments. These filaments may also be mechanically and / or chemically treated (e.g., via finishing agents) to impart desired characteristics, such as strength, elasticity, heat resistance, feel, etc., depending on the desired properties and characteristics of the resulting articles made from these filaments and yarns.

[0077] In one specific embodiment, the filament can be formed via melt spinning. Therefore, the filament can be a melt-spun filament. Typically, melt spinning involves heating a thermoplastic elastomer composition containing a thermoplastic elastomer to form a melt (also called an elastomer melt), wherein such melting can be achieved by heating the thermoplastic elastomer against a heated surface. As an example, the thermoplastic elastomer can be heated in a mixer or extruder and subsequently supplied or metered to a spinneret. The operating temperature can correspond to the melt temperature of the thermoplastic elastomer; for example, the temperature can be relatively higher than the melt temperature of the thermoplastic elastomer to allow the formation of the elastomer melt. In any case, the operating temperature can be within the range of the melt temperature of the thermoplastic elastomer as defined above.

[0078] The spinneret comprises multiple orifices or capillaries of specific dimensions and designs, which allow the formation of filaments with desired configurations and cross-sections. Therefore, this method allows for the formation of filaments of various sizes and cross-sections, including filaments with, for example, circular, elliptical, square, rectangular, leaf-shaped, or dog-boned cross-sections. A specially designed plate for filament fabrication can be formed using techniques known in the art, such as laser cutting, micro-hole drilling, laser micromachining, and microwire EDM. Furthermore, it should be understood that pre-coalescing (e.g., forming the desired cross-section through the spinneret capillaries) or post-coalescing (e.g., allowing the melt to coalesce below the front of the spinneret to form the desired cross-section) spinnerets can be used.

[0079] In this respect, any monofilament used to manufacture any multifilament herein can be a pre-coalesced monofilament or a post-coalesced monofilament. In one specific embodiment, the monofilament can be a post-coalesced monofilament, wherein the individual filaments coalesce as they leave or are drawn from the spinneret. To allow this coalescence, the filaments can be kept at a temperature above the melting temperature of the thermoplastic elastomer, thereby allowing such filaments to coalesce (or fuse) to form a monofilament, which can then be used to form a multifilament yarn. In any case, the multifilaments disclosed herein are not coalesced or fused. In this respect, the filaments constituting the multifilament yarn adhere to and contact each other at a temperature below the melting temperature of the thermoplastic elastomer, resulting in them possibly not having the ability to coalesce or fuse. Such filaments constituting the multifilament yarn can adhere to and contact each other, wherein these filaments are at a temperature above the glass transition temperature of the thermoplastic elastomer. In this respect, the filaments can (not intended to be theoretically limited) have a general tack that allows such adhesion between the filaments of the multifilament yarn.

[0080] Once extruded through the spinneret, the filament can be quenched. For example, the filament can be brought into contact with a non-reactive gas stream (e.g., air) or liquid (e.g., water) to aid in curing. As an example, the filament can be quenched while a non-reactive gas stream (such as air) is flowing across it in a generally vertical direction. In another embodiment, the filament can be quenched while a liquid is flowing across it in a relatively horizontal direction. Furthermore, in one embodiment, additional quenching may not be necessary, and sufficient quenching can be performed based on environmental conditions. The filament is then collected downstream of the spinneret using guides and can be wound up through one or more rollers.

[0081] Depending on the desired filament size, the thermoplastic elastomer can be spun at speeds ranging from about 200 to about 6000 meters per minute (m / min). When forming filaments, the spinning speed can be at least about 200 m / min, such as at least about 400 m / min, such as at least about 500 m / min, such as at least about 600 m / min, such as at least about 800 m / min, such as at least about 1000 m / min, such as at least about 2000 m / min. Spinning speeds can be approximately 6000 m / min or lower, such as approximately 5000 m / min or lower, such as approximately 4000 m / min or lower, such as approximately 3000 m / min or lower, such as approximately 2500 m / min or lower, such as approximately 2000 m / min or lower, such as approximately 1800 m / min or lower, such as approximately 1600 m / min or lower, such as approximately 1400 m / min or lower, such as approximately 1200 m / min or lower, such as approximately 1000 m / min or lower.

[0082] In addition, finishing agents can be applied to the filaments. Finishing agents can be applied to facilitate spinning and / or subsequent processing. For example, finishing agents can be applied to impart lubrication, thereby minimizing friction. Finishing agents typically comprise oils (finishing agent oils). In this regard, finishing agent oils can include, but are not limited to, silicone oils, mineral oils, ester oils, and mixtures thereof. In one embodiment, the finishing agent oil may include silicone oil. In another embodiment, the finishing agent oil may include mineral oil. In a further embodiment, the finishing agent oil may include ester oil. However, it should be understood that other finishing agent oils for thermoplastic elastomers may also be used. Furthermore, the finishing agent may also contain other additives commonly used in the art. In this regard, the finishing agent may contain salts of fatty acids, particularly metal salts of fatty acids. For example, in one embodiment, the fatty acid salt may be a stearate. Therefore, these additives in the finishing agent may include, but are not limited to, sodium palmitate, sodium stearate, magnesium stearate, potassium stearate, potassium palmitate, potassium myristate, sodium myristate, calcium stearate, calcium laurate, zinc stearate, and mixtures thereof.

[0083] If the filament is not drawn, the finishing agent can be applied before drawing the filament. Alternatively, it can be applied after quenching. In one embodiment, this application can be performed during quenching; in this case, the filament and / or yarn may have crimps, such as spiral crimps.

[0084] Finishing agents can be provided in specific amounts on the yarn. For example, the finishing agent on the yarn can be about 1 wt.% or more, such as about 2 wt.% or more, such as about 3 wt.% or more, such as about 4 wt.% or more, such as about 5 wt.% or more, such as about 6 wt.% or more, such as about 7 wt.% or more, such as about 8 wt.% or more, such as about 9 wt.% or more, based on the total weight of the yarn. The finishing agent on the yarn can also be about 20 wt.% or less, such as about 18 wt.% or less, such as about 16 wt.% or less, such as about 14 wt.% or less, such as about 12 wt.% or less, such as about 11 wt.% or less, such as about 10 wt.% or less, such as about 9 wt.% or less, such as about 8 wt.% or less, such as about 7 wt.% or less, such as about 6 wt.% or less, such as about 5 wt.% or less, based on the total weight of the yarn. Furthermore, a finishing agent may be provided on at least about 50% of the surface area of ​​the filament. For example, a finishing agent may be provided on at least about 50%, such as at least about 55%, such as at least about 60%, such as at least about 65%, such as at least about 70%, such as at least about 75%, such as at least about 80%, such as at least about 85%, such as at least about 90%, such as at least about 95% of the surface area of ​​the filament. Moreover, a finishing agent may be provided on at least about 50% of the surface area of ​​the filament. For example, a finishing agent may be provided on at least about 50%, such as at least about 55%, such as at least about 60%, such as at least about 65%, such as at least about 70%, such as at least about 75%, such as at least about 80%, such as at least about 85%, such as at least about 90%, such as at least about 95% of the surface area of ​​the filament. Not intended to be theoretically limited, such a finishing agent can assist in the cohesion of filaments within a multifilament yarn. The finishing agent on the yarn can be determined using techniques known in the art, particularly by monitoring the speed of the filament and the amount of finishing agent measured on the filament.

[0085] After extrusion from the spinneret, the filament can be drawn. Drawing can help achieve desired properties, such as increased amorphous orientation, shrinkage, modulus, and / or strength. However, it should be understood that in some embodiments, drawing may not be performed, resulting in undrawn filaments. Nevertheless, in such embodiments, these filaments can still possess certain desired properties. When performed, drawing can be carried out in combination with winding using a series of rollers or pins (some of which can typically be heated), or it can be performed as a separate stage in the filament forming process. If heated, drawing can be performed at approximately 15°C–150°C, such as approximately 15°C–130°C, such as approximately 15°C–100°C, such as approximately 15°C–80°C, such as approximately 15°C–60°C, such as approximately 15°C–40°C.

[0086] The guide roller speed (typically between the feed roller and the winding roller and can be used for drawing under certain conditions) can be from about 200 to about 6000 meters per minute (m / min). For example, the speed can be at least about 200 m / min, such as at least about 400 m / min, such as at least about 500 m / min, such as at least about 600 m / min, such as at least about 800 m / min, such as at least about 1000 m / min, such as at least about 1250 m / min, such as at least about 1500 m / min, such as at least about 1750 m / min, such as at least about 2000 m / min. The speed can be approximately 6000 m / min or lower, such as approximately 5000 m / min or lower, such as approximately 4000 m / min or lower, such as approximately 3000 m / min or lower, such as approximately 2750 m / min or lower, such as approximately 2500 m / min or lower, such as approximately 2250 m / min or lower, such as approximately 2000 m / min or lower, such as approximately 1800 m / min or lower, such as approximately 1600 m / min or lower, such as approximately 1400 m / min or lower, such as approximately 1200 m / min or lower, such as approximately 1000 m / min or lower.

[0087] The filament can be drawn at any desired draw ratio (except for draw ratios that interfere with processing by causing the filament to break) according to the desired properties. In this respect, the filament can be drawn from 0 times to about 6 times, such as from about 0.9 times to about 6 times, such as from about 1.1 times to about 6 times. For example, the filament can be drawn at 0 times or more, such as at least about 0.2 times, such as at least about 0.3 times, such as at least about 0.5 times, such as at least about 0.7 times, such as at least about 0.9 times, such as at least about 1.1 times, such as at least about 1.2 times, such as at least about 1.3 times, such as at least about 1.4 times, such as at least about 1.5 times, such as at least about 1.8 times, such as at least about 2 times, such as at least about 2.2 times, such as at least about 2.4 times, such as at least about 2.5 times. The filaments can be drawn to approximately 5 times or less, such as approximately 4.5 times or less, approximately 4 times or less, approximately 3.5 times or less, approximately 3 times or less, approximately 2.8 times or less, approximately 2.6 times or less, approximately 2.4 times or less, approximately 2.2 times or less, or approximately 2 times or less. In one embodiment, this drawing can be performed in a single step. However, in another embodiment, the filaments may not be drawn.

[0088] The resulting filaments are also suitable for further processing using additional processing equipment, or they can be used directly in applications requiring continuous filaments and / or yarns. Regarding further processing, the filaments can subsequently be converged into textured yarns using known false-twist texturing conditions or other processes. It may also be desirable to increase the surface area of ​​the filaments to provide a softer touch and enhance their breathability, thereby providing better insulation and water retention in the case of textiles. To increase the surface area, the filaments can be crimped or twisted, such as by methods like false twisting, air jetting, edge crimping, gear crimping, packing boxes, etc. In the case of elastomer yarns, a "bulking" type process of heating the yarn with minimal tension can also be performed to allow the yarn to relax and shrink, which can increase breaking elongation and thermal stability through the yarn's thermal history. The method used can be determined by the specific application of the filament.

[0089] Furthermore, after formation, the filaments can be treated by any method suitable for the desired end use. For example, particularly concerning textiles, this can include dyeing, coloring with pigments, sizing, or adding chemical agents such as antistatic agents, flame retardants, UV stabilizers, antioxidants, pigments, dyes, stain resistant agents, and / or antimicrobial agents. Additionally, the filaments can be treated to impart additional desired characteristics, such as strength, elasticity, or shrinkage. While filaments and yarns can be treated using such techniques, it should be understood that the resulting articles can also be treated using such techniques. Moreover, examples of suitable treatments and application methods can be found in Warren S. Perkins, “Textile coloration and finishing,” Carolina Academic Press, Durham, NC, 1996.

[0090] Therefore, a method for manufacturing filaments, as disclosed herein, typically includes at least the following: extruding a melt through a spinneret, the melt comprising a thermoplastic copolyester elastomer composition containing a thermoplastic copolyester elastomer; drawing the filament from the spinneret; and collecting the filament on a winding roller. Furthermore, the method may include quenching the filament with air. This quenching may occur before drawing (if drawing) the filament. Additionally, the method may include applying a finishing agent to the filament. This application may also occur before drawing (if drawing) the filament; furthermore, it may occur after quenching. Additionally, the method may include the step of drawing the filament using a drawing roller. This drawing may occur after quenching and / or after applying the finishing agent.

[0091] Furthermore, typically, the method for manufacturing multifilament yarn as disclosed herein may include at least the following: extruding a melt through a spinneret, the melt comprising a thermoplastic elastomer composition containing a thermoplastic elastomer; drawing a first filament and a second filament from the spinneret; and collecting the first filament and the second filament on a winding roller. When a third filament (or more filaments) is present, the above steps may be the same for forming the third filament. Additionally, the method may include quenching the first and second filaments with air. This quenching may be performed before drawing (if drawing) the filaments. If present, the third filament may also be quenched. Furthermore, the method may include applying a finishing agent to the first and second filaments. This application may also be performed before drawing (if drawing) the filaments; additionally, it may be performed after quenching. If present, the finishing agent may also be applied to the third filament. Additionally, the method may include the step of drawing the first and second filaments using a drawing roller. This drawing may be performed after quenching and / or after applying the finishing agent. The method may also include the step of drawing a third filament (if present). Furthermore, the method for manufacturing multifilament yarn may also include the step of converging the filaments to form a multifilament yarn.

[0092] Furthermore, according to this disclosure, a melt spinning method for spinning filaments, particularly continuous filaments, is also disclosed. In this regard, reference will be made to… Figure 1 Describe the method. Typically, Figure 1 This is a schematic diagram of an apparatus that can be used to manufacture filaments as disclosed herein. However, it should be understood that other apparatuses may also be used according to this disclosure.

[0093] Typically, this method involves passing a melt containing a thermoplastic elastomer composition (containing a thermoplastic elastomer) through a spinneret to form multiple stretchable synthetic elastomer filaments. (Reference) Figure 1 A thermoplastic elastomer composition (not shown) is fed (e.g., in granular, pellet, or other forms such as melt) into a spinneret 2 at point 1. The molten filament is extruded through the spinneret. The elastomer can be extruded from the spinneret 2 as an undrawn filament 4, which has orifices designed to provide a desired cross-section. Furthermore, the method can further include extruding the filament in any known manner (e.g., via a capillary after it exits the spinneret) after the filament has exited the capillary. Figure 1 The quenching (using cold air at point 3) is used to cool and / or solidify the filament. The diagram illustrates cross-flow quenching, where air is supplied from a direction transverse to the filament formation direction. However, any suitable quenching method can be used, such as inflow quenching, outflow quenching, and / or radial flow quenching.

[0094] These filaments can be produced using any known technology, such as... Figure 1The finishing agent is applied at the finishing agent applicators 5a and 5b shown herein using a finishing agent as defined herein. Typically, the finishing agent is applied by roller application 5a or metering application 5b. If desired, the filaments can then be drawn after quenching. The filaments can be drawn in at least one drawing step, for example in… Figure 1 The diagram schematically illustrates the drafting process between the feed roller 6 (which can operate at 150 to 1000 meters per minute) and the drafting roller 7 to form a drafted filament 8. The drafting step can be combined with spinning to produce a drafted yarn. Drafting can also be completed during the winding of the filament into a warp yarn, a process known as "draft warping." Here, the draft ratio can be the circumferential speed of the drafting roller 7 divided by the circumferential speed of the feed roller 6.

[0095] 8 filaments that may or may not be drawn can optionally be, for example, in Figure 1 Nine sections of the filament are partially relaxed using steam. Any amount of heat relaxation can be performed during spinning. In this respect, the filament can undergo dry or wet heat treatment simultaneously with relaxation to produce the desired tensile and recovery properties. This relaxation can be completed during filament production, for example, during the relaxation step described above, or after the filament has been incorporated into the yarn or fabric (e.g., during scouring, dyeing, etc.). For example, heat treatment in filament or yarn form can be performed using hot rollers or a hot box, or in a jet screen swelling step. Preferably, this heat treatment relaxation is performed after the filament is in the yarn or fabric, so that it can be processed like a non-elastic filament beforehand; however, if desired, it can be heat-treated and fully relaxed before being wound into a filament. To achieve greater uniformity in the final fabric, the filament can be uniformly heat-treated and relaxed. When the heating medium is dry air or steam, the heat treatment / relaxation temperature can range from about 80°C to about 150°C; when the heating medium is hot water, the temperature can range from about 75°C to about 100°C; and when the heating medium is atmospheric pressure steam, the temperature can range from about 101°C to about 115°C. Generally, lower temperatures may result in too little or no heat treatment, while higher temperatures may melt the thermoplastic elastomer. Furthermore, the heat treatment / relaxation step can typically be completed within seconds. Without being limited, generally the greater the relaxation, the greater the elasticity of the filament, and the less shrinkage that may occur in downstream operations. Furthermore, without being limited, this treatment can also allow the resulting articles (e.g., garments), fabrics, and / or yarns to be thermally stable for post-processing (e.g., screen printing, sublimation dyeing, etc.).

[0096] Furthermore, filament relaxation can be achieved using rollers present within the process. For example, as disclosed herein, the process may include a feed roller to which the filament can be drawn from the spinneret. The process may also include a drafting roller or guide roller following the feed roller. Finally, the filament / yarn can be wound by a winding roller. By controlling the speed of the respective rollers, the filament and / or yarn can have relaxation opportunities. For example, in one embodiment, the feed roller speed may be greater than the drafting roller speed, or greater than the guide roller speed if there is no drafting. In one embodiment, the drafting roller speed, or the guide roller speed if there is no drafting, may be greater than the winding roller speed. In a further embodiment, the feed roller speed may be greater than the drafting roller speed, or greater than the guide roller speed if there is no drafting, and the drafting roller speed, or the guide roller speed if there is no drafting, may be greater than the winding roller speed.

[0097] Then it can be done in Figure 1 The winding machine has 11 winding points to collect quenched, optionally drawn, and optionally relaxed filaments. The winding machine can also be referred to as a take-up roller. Winding speeds can range from about 200 to about 6000 meters per minute (m / min). For example, winding speeds can be at least about 200 m / min, such as at least about 400 m / min, such as at least about 500 m / min, such as at least about 600 m / min, such as at least about 800 m / min, such as at least about 1000 m / min, such as at least about 1250 m / min, such as at least about 1500 m / min, such as at least about 1750 m / min, such as at least about 2000 m / min. The winding speed can be approximately 6000 m / min or lower, such as approximately 5000 m / min or lower, such as approximately 4000 m / min or lower, such as approximately 3000 m / min or lower, such as approximately 2750 m / min or lower, such as approximately 2500 m / min or lower, such as approximately 2250 m / min or lower, such as approximately 2000 m / min or lower, such as approximately 1800 m / min or lower, such as approximately 1600 m / min or lower, such as approximately 1400 m / min or lower, such as approximately 1200 m / min or lower, such as approximately 1000 m / min or lower.

[0098] In one embodiment, the winding speed may be less than the speed of the draft (or guide) rollers. For example, the speed of the draft (or guide) rollers may be 75% or higher, such as 80% or higher, such as 85% or higher, such as 88% or higher, such as 90% or higher, such as 92% or higher, such as 94% or higher, such as 95% or higher, such as 96% or higher, such as 97% or higher, such as 97.5% or higher, such as 98% or higher, such as 98.5% or higher, such as 99% or higher, up to less than 100% of the winding speed. Not intended to be theoretically limited, it is believed that such speed differences can allow one or more filaments and yarns to have the opportunity to be at least partially relaxed.

[0099] If multiple filaments have already been spun and quenched, these filaments can be brought together, optionally interwoven, and then wound. For example, this gathering and / or interweaving can be performed to form a multifilament yarn. Single filaments or multifilament yarns can be... Figure 1 The winding machine 11 winds in the same manner. In the case of multiple filaments that have already been spun and quenched, these filaments can be gathered and optionally interwoven before winding, as is done in the art. Gathering can occur at multiple points in the process. For example, gathering can occur at the feed roller or before the feed roller, such as at the finishing agent applicator.

[0100] As noted in this article, filaments can be used to manufacture yarns. Yarns can include, but are not limited to, multiple filaments twisted together (spun yarns), multiple filaments joined together without twist (zero-twist yarns), and multiple filaments joined together with a certain degree of twist.

[0101] In one embodiment, the multifilament yarn as disclosed herein may have no twist. In another embodiment, the multifilament yarn as disclosed herein may have a relatively low degree of twist. For example, the twist may be 1 twist per inch or less, such as 0.9 twist per inch or less, such as 0.8 twist per inch or less, such as 0.7 twist per inch or less, such as 0.6 twist per inch or less, such as 0.5 twist per inch or less, such as 0.4 twist per inch or less, such as 0.3 twist per inch or less, such as 0.2 twist per inch or less, such as 0.1 twist per inch or less, such as 0.05 twist per inch or less, such as 0.01 twist per inch or less. The twist may be 0 twist per inch or more, such as 0.01 twist per inch or more, such as 0.05 twist per inch or more, such as 0.1 twist per inch or more, such as 0.2 twist per inch or more, such as 0.3 twist per inch or more, such as 0.4 twist per inch or more, such as 0.5 twist per inch or more.

[0102] Furthermore, multifilament yarns can have minimal entanglement. For example, interwoven yarns can be characterized by entanglement points (called knots) that are separated by spaces of unentangled filaments. In this respect, the distance between the end of the first knot and the beginning of the second knot in a multifilament yarn, as disclosed herein, can be relatively long. Furthermore, the average distance between the knots in a multifilament yarn can be relatively long. For example, this distance can be about 1 inch or longer, such as about 2 inches or longer, such as about 3 inches or longer, such as about 4 inches or longer, such as about 5 inches or longer, such as about 6 inches or longer, such as about 8 inches or longer, such as about 10 inches or longer, such as about 12 inches or longer, such as about 16 inches or longer, such as about 20 inches or longer, such as about 24 inches or longer, such as about 30 inches or longer, such as about 36 inches or longer, such as about 42 inches or longer, such as about 48 inches or longer, such as about 54 inches or longer, or about 60 inches or longer.

[0103] As noted herein, yarns can typically have any filament count used to form multifilament yarns. For example, a yarn is a multifilament yarn formed from two or more filaments, wherein these two or more filaments can be wound to form the yarn. Thus, a multifilament yarn includes a first filament at least partially adhered to a second filament. Furthermore, a multifilament yarn may further include a third filament, wherein the third filament is at least partially adhered to the first filament, the second filament, or both. In particular, a multifilament yarn may include a first filament, a second filament, and a third filament, wherein such filaments are at least partially adhered to each other. In this regard, in one embodiment, such filaments may simply adhere to each other, wherein such adhesion points between filaments may not involve fusion, wherein fusion is defined as combining or joining filaments at a temperature exceeding the polymer melting temperature.

[0104] In this respect, multifilament yarn may include at least about 2 filaments. Multifilament yarn may include about 2 or more, such as about 3 or more, such as about 5 or more, such as about 10 or more, such as about 15 or more, such as about 20 or more, such as about 25 or more filaments, such as about 50 or more, such as about 100 or more filaments. Multifilament yarn may include about 200 or fewer, such as about 100 or fewer, such as about 80 or fewer, such as about 60 or fewer, such as about 50 or fewer, such as about 40 or fewer, such as about 35 or fewer, such as about 30 or fewer, such as about 25 or fewer, such as about 20 or fewer, such as about 15 or fewer, such as about 10 or fewer, such as about 5 or fewer, such as about 4 or fewer, such as about 3 or fewer filaments.

[0105] The yarn can have a total denier number from about 1 to about 2000. For example, the total denier number can be about 1 or greater, such as about 5 or greater, such as about 10 or greater, such as about 20 or greater, such as about 30 or greater, such as about 40 or greater, such as about 50 or greater, such as about 70 or greater, such as about 100 or greater, such as about 120 or greater, such as about 140 or greater, such as about 160 or greater, such as about 180 or greater, such as about 200 or greater, such as about 300 or greater, such as about 500 or greater, such as about 800 or greater, such as about 1000 or greater, such as about 1300 or greater, such as about 1500 or greater, such as about 1800 or greater, such as about 2000 or greater. The total denier number can be approximately 3000 or less, such as approximately 2800 or less, such as approximately 2500 or less, such as approximately 2200 or less, such as approximately 2000 or less, such as approximately 1800 or less, such as approximately 1600 or less, such as approximately 1400 or less, such as approximately 1200 or less, such as approximately 1000 or less, such as approximately 800 or less, such as approximately 600 or less, such as approximately 500 or less, such as approximately 450 or less, such as approximately 400 or less, such as approximately 350 or less, such as approximately 300 or less, such as approximately 275 or less, such as approximately 250 or less, such as approximately 225 or less, such as approximately 200 or less, such as approximately 180 or less, such as approximately 160 or less, such as approximately 140 or less, such as approximately 120 or less, such as approximately 100 or less, such as approximately 80 or less, such as approximately 60 or less, such as approximately 50 or less. Denier number can be determined at a temperature of about 23°C according to D2259-02 (2016).

[0106] In addition, the yarn can have a specific linear density because it involves the filaments that make up the yarn. For example, the yarn can have at least about 0.1 denier per filament (dpf), such as at least about 0.2 dpf, such as at least about 0.5 dpf, such as at least about 0.7 dpf, such as at least about 1 dpf, such as at least about 2 dpf, such as at least about 3 dpf, such as at least about 4 dpf, such as at least about 5 dpf, such as at least about 8 dpf, such as at least about 10 dpf, such as at least about 20 dpf, such as at least about 30 dpf, such as at least about 50 dpf, such as at least about 70 dpf, such as at least about 90 dpf, such as at least about 110 dpf, such as at least about 130 dpf, such as at least about 150 dpf. The yarn can have a strength of approximately 500 dpf or less, such as approximately 450 dpf or less, such as approximately 400 dpf or less, such as approximately 350 dpf or less, such as approximately 300 dpf or less, such as approximately 250 dpf or less, such as approximately 200 dpf or less, such as approximately 180 dpf or less, such as approximately 150 dpf or less, such as 130 dpf or less, such as 110 dpf or less, such as 100 dpf or less, such as 90 dpf or less, such as 80 dpf or less, such as 70 dpf or less, such as 60 dpf or less, such as 50 dpf or less, such as approximately 40 dpf or less, such as approximately 35 dpf or less, such as approximately 25 dpf or less, such as approximately 22 dpf or less, such as about 20 dpf or less, such as about 18 dpf or less, such as about 16 dpf or less, such as about 14 dpf or less, such as about 12 dpf or less, such as about 10 dpf or less, such as about 8 dpf or less, such as about 6 dpf or less, such as about 5 dpf or less, such as about 4 dpf or less, such as about 3.5 dpf or less, such as about 3 dpf or less, such as about 2.5 dpf or less. Not intended to be limiting, the dpf for a particular application may be relatively lower than for other applications. For example, the dpf for textile applications may be relatively lower than that for industrial applications. In any case, the dimensions and strength of this filament can be readily determined using methods generally known in the art.

[0107] As noted herein, filaments can have a specific cross-section determined by the spinneret design. Typically, filaments can have a core extending along the continuous length of the filament. In this regard, in one embodiment, the core can comprise a thermoplastic elastomer as defined herein. In another embodiment, the core of the filament can be hollow, such that it does not comprise a thermoplastic elastomer or composition as defined herein.

[0108] In one embodiment, the filament may typically have a circular cross-section. In another embodiment, the filament may typically have a non-circular cross-section. For example, the filament may typically have an elliptical cross-section. However, it should be understood that other non-circular cross-sections may also be formed from thermoplastic elastomers as disclosed herein.

[0109] In another embodiment, the filament may be multi-lobed. For example, the filament may include two or more lobes. Such lobes may be arranged radially from the core. In this respect, these lobes may extend from the central portion of the filament or the core, wherein each lobe has a proximal end adjacent to the central portion and a distal end radially spaced from the proximal end. Furthermore, each lobe may have a convex curve. In this respect, each lobe may not have a relatively flat surface.

[0110] Furthermore, in one embodiment, each lobe may be directly connected to each other. In this respect, such a connection point between adjacent lobes may be referred to as a cusp. Alternatively, adjacent lobes may not be directly connected. Such a region connecting two adjacent lobes may be referred to as a lobe connection. Such a lobe connection may also have a relatively convex curve. Similar to these lobes, such a lobe connection may also not have a relatively flat surface.

[0111] Furthermore, the leaflets can be positioned symmetrically around the circumference of the filament. In other words, in one embodiment, the filament can have a symmetrical cross-section. In another embodiment, the filament can have an asymmetrical cross-section. Additionally, the leaflets can be asymmetrical or symmetrical. In one embodiment, the leaflets can be asymmetrical. In another embodiment, the leaflets can be symmetrical.

[0112] In one embodiment, the filament may have a core / skin configuration. For example, the core may be formed from a thermoplastic elastomer composition as defined herein. This composition may be referred to as a first thermoplastic elastomer composition. Furthermore, the skin may be formed from a second thermoplastic elastomer composition. This second thermoplastic elastomer composition may differ from the first thermoplastic elastomer composition in at least one respect. For example, even though both may contain thermoplastic elastomers as defined herein, the corresponding properties of each thermoplastic elastomer may differ. In this respect, the first thermoplastic elastomer composition may contain a first thermoplastic elastomer, and the second thermoplastic elastomer composition may contain a second thermoplastic elastomer, wherein the first thermoplastic elastomer differs from the second thermoplastic elastomer in at least one respect.

[0113] Furthermore, as noted herein, the filament may include two or more lobes arranged radially around the core. In this respect, the lobes may be formed of a second thermoplastic elastomer composition and a second thermoplastic elastomer. For example, the core may be formed of a first thermoplastic elastomer composition and a first thermoplastic elastomer, and the skin (including the lobes) may be formed of a second thermoplastic elastomer composition and a second thermoplastic elastomer.

[0114] Examples of various cross-sections of monofilaments are shown in Figure 2A , 2B Among 3A, 3B, 3C, 4A, 4B, and 4C. For example, Figure 2A and 2B It shows a double-leaf cross section. Figure 3A , 3B 3C showcased a trilobal cross-section, and Figure 4A , 4B 4C and 4C demonstrate a four-lobed cross-section. Each cross-section and configuration includes lobes extending radially from the filament core.

[0115] refer to Figure 2A and 2B The filament 200 has a double-leaf cross-section. Specifically, the filament 200 includes two leaflets 210. Figure 2A In the middle, the lobes 210 are directly connected to each other at the apex 220. Figure 2B In this configuration, the leaflets 210 are not directly connected to each other. In this respect, they are indirectly connected to each other via the leaflet connection area 230.

[0116] refer to Figure 3A , 3B Like 3C, the filament 300 has a trilobal cross-section. Specifically, the filament 300 includes three lobes 310. Figure 3A and Figure 3C In the middle, the lobes 310 are directly connected to each other at the apex 320. Figure 3B In this configuration, the leaflets 310 are not directly connected to each other. Instead, they are indirectly connected via the leaflet connection region 330. Furthermore, in... Figure 3C In the middle, the petals 310 converge at the tip 320, while providing the hollow core 340.

[0117] refer to Figure 4A , 4B And 4C, filament 400 has a four-lobed cross-section. Specifically, filament 400 includes four lobes 410. Figure 4A and Figure 4C In the middle, the lobes 410 are directly connected to each other at the apex 420. Figure 4B In this configuration, the leaflets 410 are not directly connected to each other. Instead, they are indirectly connected via leaflet connecting regions 430. Furthermore, in... Figure 3CIn the middle, the petals 410 converge at the apex 420, while providing the hollow core 440.

[0118] Examples of various multifilament yarns are shown in Figure 2C , 5 And 6. For example, Figure 2C A double-filament multifilament yarn 2000 is shown. Specifically, the multifilament yarn 2000 comprises two separate filaments 2100 that are adhered to each other but may not necessarily coalesce. Relatedly, Figure 5 A three-filament multifilament yarn 3000 was demonstrated. Specifically, the multifilament yarn 3000 comprises three individual filaments 3100 that are adhered to each other and may not necessarily converge. Furthermore, the multifilament yarn 3000 includes a hollow core 3400. Similarly, Figure 6 A four-filament multifilament yarn 4000 is shown. Specifically, the multifilament yarn 4000 comprises four individual filaments 4100 that are adhered to each other and may not necessarily be aggregated. In addition, the multifilament yarn 4000 includes a hollow core 4400.

[0119] like Figure 2C , 5 As shown in Figure 6, each individual filament within a multifilament yarn has a relatively circular cross-section. However, it should be understood that filaments with non-circular cross-sections (such as...) Figure 2A , 2B Those shown in 3A, 3B, 3C, 4A, 4B and 4C can be used to manufacture multifilament yarns for use in articles as disclosed herein. III. Articles of Manufacture

[0120] The inventors of this invention have discovered that the advantageous properties of filaments and yarns, as disclosed herein, allow them to be used to form a wide variety of articles for a wide range of applications. In this regard, filaments can be used to form yarns that can be used to prepare woven, knitted, and / or nonwoven articles, which can be prepared using conventional techniques, including but not limited to meltblowing, spunbonding, carding and bonding (including thermal bonding (hot air bonding and dot bonding)), air entanglement, and other techniques. For example, they can withstand a variety of high-speed conditions used to form such articles.

[0121] Furthermore, the yarn configuration can vary depending on the specific application. For example, the yarn can be used as a bare yarn or a covered yarn. In one embodiment, the yarn itself can be used as a bare yarn. Alternatively, the yarn can be used as a covered yarn, wherein the yarn described herein can be used as the core. For such a covered yarn, inelastic filaments or yarns or short fiber yarns can be wrapped around the core, particularly in a helical manner. Additionally or alternatively, another elastic yarn can be used for the cover.

[0122] As an example, yarn can be used in textile fabrics for clothing and interior decoration. For instance, yarn can be stretchable and exhibit the desired resilience that might be desirable for such applications. In this respect, yarn can be used in textiles. In particular, yarn can be used to manufacture fabrics such as knitted or woven fabrics. Therefore, yarn can be considered as knittable yarn, especially knittable, stretchable yarn.

[0123] The knitting construction of yarns is not necessarily limited to this disclosure. For example, various types of knitting constructions as known in the art can be used to form fabrics and / or articles of the result using filaments and yarns as disclosed herein. By way of some examples only, knitting constructions can be those disclosed in U.S. Patent Nos. 9,689,092, 10,370,782, or 2021 / 0254244, all of which are hereby incorporated in their entirety.

[0124] In one specific embodiment, the knitted construction may be a circular knitted construction. Not intended to be limiting, articles formed from fabrics with a circular knitted construction may be more comfortable than those with other knitted constructions, partly due to the fabric's stretchability. For example, when force is applied, a circular knitted fabric may stretch slightly due to compression and / or elongation that may occur within the fabric's seams / loops, and can then recover its original shape.

[0125] Knitting is generally the process of constructing a fabric by interlocking a series of loops (turns) made of one or more strands of yarn in the warp and weft. Knitting typically includes warp knitting and weft knitting. In warp knitting, multiple strands of yarn extend longitudinally through the fabric to form all the loops. In weft knitting, a single continuous strand of yarn extends laterally through the fabric, thus forming all the loops in one row. Weft knitting involves fabrics formed on both circular and flat knitting machines. On a circular knitting machine, the fabric is produced in a tubular form, with the yarns extending continuously around the fabric. On a flat knitting machine, the fabric is produced in a flat form, with the yarns alternating back and forth through the fabric. The resulting textile consists of an inner (processed reverse) and an outer (processed front), each layer formed by the same or different strands and / or threads. By way of example, knitted structures can be single-knit / plain-knit fabrics, double-knit / plain-knit fabrics, and / or coated fabrics (with yarns of different properties arranged on the front and back sides).

[0126] Textiles can be formed by weft knitting, in which a continuous yarn extends laterally through the fabric, thereby creating all the loops in a row. Preferably, weft-knitted textiles are formed by circular knitting, in which the textile is produced in the form of a tubular structure, with the yarn extending continuously around the textile.

[0127] refer to Figure 7The textile has a knitted structure 500 constructed in rows 505A, 505B, 505C and longitudinal rows 510A, 510B, 510C, each row being formed by ply yarns. The term "ply yarn" includes a single yarn (a continuous ply of one or more textile filaments in a form suitable for knitting, weaving, or otherwise braiding to form a textile fabric). In an embodiment, the knitted structure 500 includes a first ply yarn 515. As shown, the ply yarn 515 forms a plurality of rows 505 within the knitted structure 500, and particularly forms a plurality of successive rows 505. In one embodiment of the knitted structure 500, at least one ply yarn 515 may be formed from a thermoplastic elastomer-based yarn as disclosed herein. In one embodiment, all ply yarns 515 within the knitted structure may be formed from a thermoplastic elastomer-based yarn as disclosed herein.

[0128] However, while this may be the case, it should be understood that other types of ply yarns and yarns may also be used. For example, in the knitted structure 500, in one embodiment, at least one ply yarn 515 may be another type of ply yarn typically used in the art, rather than the thermoplastic elastomer-based yarn disclosed herein. For example, in one embodiment, this ply yarn may be another type of elastic ply yarn. These may include ply yarns of anidex fibers, elastomeric esters, bicomponent filament rubbers, and combinations thereof. By a specific example, polyurethane elastane may be used, i.e., man-made fibers in which the fiber-forming material is a long-chain synthetic polymer consisting of at least 85% segmental polyurethane. Alternatively, in one embodiment, this ply yarn may be an inelastic ply yarn typically not formed of an elastomeric material. These fibers can include natural fibers, including cellulose fibers (e.g., cotton, bamboo) and protein fibers (e.g., wool, silk, and soybean), as well as synthetic fibers, including polyester fibers (poly(ethylene terephthalate) fibers and poly(propylene terephthalate) fibers), polycaprolactam fibers, poly(hexamethylene adipamide) fibers, acrylic fibers, acetate fibers, rayon fibers, nylon fibers, and combinations thereof.

[0129] In this regard, when other yarns are used in the knitted structure, yarns 505 formed from thermoplastic elastomer-based yarns as disclosed herein can be formed approximately every second to every eleventh row 505 (e.g., yarns placed every 4th to 10th rows). Preferably, such yarns can be formed every fourth, fifth, or sixth row 505 within the knitted structure 500. Typically, the spacing can be kept consistent throughout the knitted structure 500. In other embodiments, the spacing of such yarns 505 can be varied to alter the recovery and / or stretch properties of the entire article (e.g., garment). By a specific example, such yarns 515 can form every fourth row 505 of the article for one part of the article, but every sixth row along another part of the article.

[0130] In a further embodiment, each strand 515 may comprise a strand formed of a thermoplastic elastomer as disclosed herein, which is paired with a corresponding strand 515 (e.g., these strands are braided or otherwise blended). The strand pairs are then used to form rows 505 within the knitted structure 500.

[0131] In any configuration, the amount of strand 515 formed of the thermoplastic elastomer as disclosed herein may be present in the knitted structure in an amount of about 0.1% or more, about 0.5% or more, about 1% or more, about 2% or more, about 3% or more, about 5% or more, about 10% or more, about 15% or more, about 20% or more, about 25% or more, about 30% or more, about 40% or more, about 50% or more, about 60% or more, about 70% or more, about 80% or more, about 90% or more, about 95% or more, or about 100% by weight. Such stock lines may be present in amounts of approximately 100% or less by weight, such as approximately 98% or less, such as approximately 95% or less, such as approximately 90% or less, such as approximately 80% or less, such as approximately 75% or less, such as approximately 70% or less, such as approximately 65% ​​or less, such as approximately 60% or less, such as approximately 55% or less, such as approximately 50% or less, such as approximately 45% or less, such as approximately 40% or less, such as approximately 35% or less, such as approximately 30% or less, such as approximately 25% or less, such as approximately 20% or less, such as approximately 15% or less, such as approximately 10% or less, such as approximately 5% or less.

[0132] Knitted structures can also be double-knitted structures. Typically, this type of structure can be formed on a knitting machine with two needle beds. These machines can include, but are not limited to, V-bed plain knitting machines, double-knit circular knitting machines, etc. A double-knitted structure can provide a working front knitted on one of the needle beds and a working back knitted on the remaining needle beds of the knitting machine. When observing the working front and back of a double-knitted structure, both sides may appear to resemble the working front of a single-knitted plain knit fabric and contain working loops or weft knitting loops. In some embodiments, connecting yarns can be used to connect the working front and back of the double-knitted structure, wherein the connecting yarns pass back and forth between two different needle beds. Double-knitted structures can be formed on machines in which the needles in one bed are directly opposite the needles in the other bed (referred to as interlock gaiting). Double-knitted structures can also be formed on machines in which the needles in one bed are directly opposite the space in the other bed (referred to as rib gaiting).

[0133] In the above-described double-knitted structure, the process-faced side can form the outward-facing surface of the resulting article, and the process-reverse side can form the inward-facing surface of the resulting article. The process-faced side of this structure can be formed from a first yarn. The first yarn can be any type of yarn commonly used in yarns, such as inelastic or elastic yarns, for example, the yarns disclosed herein. Inelastic yarns can include polyamide yarns, cotton yarns, and / or polyester yarns. The process-reverse side of this structure can be formed from a second yarn and optionally the first yarn. The second yarn can be an elastic yarn, as disclosed herein.

[0134] In this configuration, the amount of the second elastic yarn may be present in the knitted structure in an amount of about 0.1% or more, such as about 0.5% or more, such as about 1% or more, such as about 2% or more, such as about 3% or more, such as about 5% or more, such as about 10% or more, such as about 15% or more, such as about 20% or more, such as about 25% or more, such as about 30% or more, such as about 40% or more, such as about 50% or more, such as about 60% or more, such as about 70% or more, such as about 80% or more, such as about 90% or more, such as about 95% or more, such as about 100% by weight. This yarn may be present in amounts of about 100% or less by weight, such as about 98% or less, such as about 95% or less, such as about 90% or less, such as about 80% or less, such as about 75% or less, such as about 70% or less, such as about 65% or less, such as about 60% or less, such as about 55% or less, such as about 50% or less, such as about 45% or less, such as about 40% or less, such as about 35% or less, such as about 30% or less, such as about 25% or less, such as about 20% or less, such as about 15% or less, such as about 10% or less, such as about 5% or less.

[0135] Knitted structure, whether based on Figure 7 The structure, or any other structure as described herein, can be incorporated into garment articles. Garments are not necessarily limited to the limitations of this disclosure. For example, garments can be tubular knitted fabrics, which are fabrics knitted with a desired three-dimensional configuration, rather than two-dimensional fabrics that are cut, sewn, and otherwise manipulated to produce a three-dimensional configuration. However, it should be understood that yarns and fabrics can also be used in two-dimensional fabrics.

[0136] In this regard, clothing or garments may include, but are not limited to, short-sleeved or long-sleeved shirts, vests, undershirts, jackets, coats, trousers, pants, shorts, socks, underwear, nylon stockings / leggings, dresses, skirts, hats / headwear, outerwear, etc. Other garment or garment products include, but are not limited to, pajamas, swimwear, compression clothing, denim, stretch garments (including sportswear), etc. Besides clothing, other uses of these fabrics include, but are not limited to, furniture upholstery, curtains, toys, automotive fittings, furniture, equipment, etc. Test Methods

[0137] Elongation at break and toughness: Elongation at break and toughness were determined according to ASTM D2653-07 (2018) at a temperature of approximately 23°C. For the apparatus used to perform the test, Option A under the clamping assembly was used. The gauge length used on the tensile testing machine was approximately 2 inches. For this test, ten specimens were tested, and the average value was recorded.

[0138] Denier number and fiber shrinkage: Denier number and fiber shrinkage were determined according to ASTM D2259-02 (2016). Denier number was determined at approximately 23°C. For these tests, 90 wraps were performed while carefully securing the loose ends without introducing additional tension in the skein and cutting any excess yarn. To determine the denier number, the skein was placed on a balance to record the weight and obtain a denier value based on the skein length according to standard methods. Additionally, fiber shrinkage was determined using dry heat exposure at approximately 120°C according to step 13 of section 6.6.1. Specifically, the skein was suspended inside an oven and allowed to relax under heat for 15 minutes. Afterward, the length of the skein was measured to determine the amount of shrinkage. Examples Example 1

[0139] according to Figure 1 The general schematic diagram shown illustrates a thermoplastic coether ester elastomer (flexural modulus - 45 MPa; hardness - 33 Shore D; Tm - 193°C; density - 1.1 g / cm³). 3The process involves spinning to form a multifilament yarn composed of three filaments. Specifically, granules of thermoplastic coether ester elastomer are fed into an extruder and heated. The extruder comprises a screw zone and heating zones as follows: zone 1 - 215°C, zone 2 - 225°C, zone 3 - 235°C, zone 4 - 250°C, and zone 5 - 260°C. The molten elastomer is fed into a spinneret assembly operating at approximately 260°C, the spinneret assembly comprising four spinnerets, each having three die orifices. The melt is fed using a melt pump operating at 5.5 rpm, delivering approximately 4.114 g / min to each of the four spinnerets. The spinneret includes 0.028" diameter die holes that are appropriately spaced to allow the extrusion of three distinct filaments to form a multifilament yarn. After exiting the spinneret, the filaments are cooled using ambient quenching without the addition of a quenching airflow. Ceramic guides (0.5 mm, 3-dimpled low-friction guides) are used to guide the filaments and also act as a finishing agent applicator. The ceramic guides also allow the filaments to aggregate together and adhere at least partially to each other at a temperature below the melting temperature of the hard segments of the thermoplastic coether ester elastomer but above the glass transition temperature. The finishing agent applicator is positioned approximately 11.5 feet from the surface of the spinneret assembly. In the finishing agent applicator, a silicone finishing agent (pumped at 0.189 g / min) is applied to the filaments at an amount of approximately 4.4 wt.% based on the total weight of the yarn. The feed roller speed is approximately 1000 m / min, and the winding speed is approximately 1000 m / min. The speed is approximately 1100 m / min, and the drafting (or guide) roller between the winding machine and the feed roller is approximately 1100 m / min. When the winding machine speed is less than the guide roller speed, the filament and yarn have the opportunity to loosen at least partially.

[0140] The spinning process produces a 40 denier multifilament yarn. In addition, the yarn exhibits the following properties: tenacity - 1.04 g / d; elongation at break - 393%; and shrinkage - 7.9%. Figure 8 Optical micrographs of the multifilament yarns, highlighted within each circle, are provided. Specifically, the micrographs show that the three extruded filaments are not coalesced, but rather at least partially adhered to form the multifilament yarn. The yarn was then knitted at commercial speed on a Monarch 30 specification 32" machine to produce a fabric free of yarn or fabric defects.

[0141] These and other modifications and variations of this disclosure can be practiced by those skilled in the art without departing from the spirit and scope thereof. Furthermore, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Moreover, those skilled in the art will understand that the foregoing description is merely illustrative and not intended to limit the invention (as further described in the appended claims).

Claims

1. A multifilament yarn comprising a first filament at least partially adhered to a second filament, wherein the first filament and the second filament are each formed of a thermoplastic elastomer composition comprising a thermoplastic elastomer exhibiting a flexural modulus of about 300 MPa or less as measured according to ISO 178:2019 at a temperature of about 23°C, and further wherein the yarn has a linear density of about 1 to about 500 deniers per filament and exhibits an elongation at break of about 300% or greater as measured according to ASTM D2653-07 (2018) at a temperature of about 23°C.

2. The multifilament yarn as described in any of the preceding claims, wherein, This multifilament yarn exhibits properties as per ASTM D2259-02 (2016) (section) 6.6.1 - Shrinkage of approximately 50% or less as determined by dry heat exposure.

3. The multifilament yarn as described in any of the preceding claims, wherein, The multifilament yarn exhibits a toughness of approximately 0.7 g / denier or greater, as measured according to ASTM D2653-07 (2018) at a temperature of approximately 23°C.

4. The multifilament yarn as described in any of the preceding claims, wherein, The multifilament yarn exhibits a recoverable elongation of at least approximately 75%, as determined according to ASTM D6720-07 (2018).

5. The multifilament yarn as described in any of the preceding claims, wherein, The thermoplastic elastomer exhibits one or more of the following: a Shore D hardness of about 60 or less as determined according to ISO 868:2003 (15-second test time) at a temperature of about 23°C; a melt temperature from about 100°C to about 230°C as determined according to ISO 11357-3:2018; or a tensile stress at break of about 45 MPa or less as determined according to ISO 527-1 / -2 (2012) at a temperature of about 23°C.

6. The multifilament yarn as described in any of the preceding claims, wherein, This thermoplastic elastomer is a thermoplastic copolyether ester elastomer.

7. The multifilament yarn as described in any of the preceding claims, wherein, The thermoplastic elastomer is a thermoplastic copolyester elastomer containing hard segments and soft segments, wherein the hard segments constitute from about 20 wt.% or more to about 70 wt.% or less of the thermoplastic copolyester elastomer, and the soft segments constitute from about 30 wt.% or more to about 80 wt.% or less of the thermoplastic copolyester elastomer.

8. The multifilament yarn as described in any of the preceding claims, wherein, The thermoplastic elastomer is a thermoplastic copolyester elastomer containing hard segments and soft segments, wherein the hard segments are derived from at least one aromatic dicarboxylic acid and / or its diester and at least one diol containing 2 to 15 carbon atoms.

9. The multifilament yarn as described in claim 8, wherein, The aromatic dicarboxylic acid includes terephthalic acid, isophthalic acid, or combinations thereof, and the diol includes ethylene glycol, 1,4-butanediol, 1,3-propanediol, or combinations thereof.

10. The multifilament yarn as described in any of the preceding claims, wherein, The thermoplastic elastomer is a thermoplastic copolyester elastomer containing hard segments and soft segments, wherein these soft segments are derived from at least one aromatic dicarboxylic acid and / or its diester and at least one poly(alkylene oxide) glycol.

11. The multifilament yarn as described in claim 10, wherein, The aromatic dicarboxylic acid includes terephthalic acid, isophthalic acid, or combinations thereof, and the poly(alkyleneoxy) glycol includes poly(tetramethyleneoxy) glycol, poly(trimethyleneoxy) glycol, poly(propyleneoxy) glycol, poly(ethyleneoxy) glycol, poly(hexamethyleneoxy) glycol, or combinations thereof.

12. The multifilament yarn as described in any of the preceding claims, wherein, The thermoplastic elastomer includes a thermoplastic coether ester elastomer prepared from monomers comprising: (1) poly(tetramethyleneoxy) glycol, (2) a dicarboxylic acid selected from isophthalic acid, terephthalic acid or mixtures thereof, and (3) a diol selected from 1,4-butanediol, 1,3-propanediol or mixtures thereof.

13. The multifilament yarn as described in any of the preceding claims, wherein, The first filament and the second filament are coated with a finishing agent.

14. The multifilament yarn as described in claim 13, wherein, This finishing agent contains a finishing oil with silicone oil.

15. The multifilament yarn as described in claim 13, wherein, The finishing agent is applied to at least about 50% of the surface area of ​​the first filament and the second filament.

16. The multifilament yarn as described in any of the preceding claims, wherein, The multifilament yarn further includes a third filament that is at least partially adhered to the first filament, the second filament, or both.

17. The multifilament yarn as described in claim 16, wherein, The first filament, the second filament, and the third filament are at least partially adhered to each other.

18. A method for manufacturing multifilament yarn as described in any of the preceding claims, the method comprising: The melt is extruded through a spinneret, the melt comprising the thermoplastic elastomer composition containing the thermoplastic elastomer; The first and second filaments are drawn from the spinneret into the feed roller; The first filament and the second filament were quenched with air. A finishing agent is applied to the first filament and the second filament; as well as The first filament and the second filament are collected on the winding roller.

19. The method of claim 18, further comprising: The first filament and the second filament are drawn using a drawing roller.

20. The method of claim 19, wherein, The feed roller speed is greater than the draw roller speed, and / or the draw roller speed is greater than the winding roller speed.

Images