Fibers containing reinforcing additives and recycled content

Abstract

Disclosed is a fiber composition comprising about 60 wt.% to about 99 wt.% of a polymeric resin comprising a chemically upcycled polybutylene terephthalate (PBT) component derived from post-consumer recycled (PCR) polyester, and about 0.1 wt.% to about 40 wt.% of a reinforcing filler, wherein the combined weight percentage of all components does not exceed 100 wt.%, and all weight percentages are based on the total weight of the fiber composition, and wherein the fiber composition is in the form of a fiber, and the fiber exhibits a tensile modulus of greater than 1950 MPa when tested in accordance with ISO 527.

Description

[Technical field]

[0001] The present disclosure relates to fibers comprising recycled materials, and in particular to fibers comprising recycled materials and reinforcing additives. [Background technology]

[0002] Polymer filaments, fibers, and other very fine polymer extrudates can be used in many applications. Generally, polybutylene terephthalate (PBT) is highly flexible, elastic, and easy to process, and is therefore used in high-end fiber applications. As more sustainable materials are increasingly sought after, post-consumer recycled polymers, including post-consumer recycled (PCR) PBT, are increasingly desired for fiber applications. Fibers spun from certain post-consumer recycled PBT resins typically exhibit poor mechanical properties, as evidenced by lower stress / modulus and thermal stability when compared to virgin PBT. There remains a need in the art for recycled polymer filaments that exhibit improved mechanical properties.

[0003] Aspects of the present disclosure address these and other needs. Summary of the Invention [Means for solving the problem]

[0004] An embodiment of the present disclosure relates to a fiber composition comprising: about 60 wt.% to about 99 wt.% of a polymeric resin; and about 0.1 wt.% to about 40 wt.% of a reinforcing filler, wherein the combined weight percentage of all components does not exceed 100 wt.%, and all weight percentages are based on the total weight of the fiber composition, the fiber composition is in the form of a fiber, and the fiber exhibits a tensile modulus of greater than 1950 MPa when tested in accordance with ISO 527.

[0005] In a further aspect, the present disclosure relates to a melt spun monofilament comprising about 60 wt.% to about 99 wt.% polymeric resin; and about 0.1 wt.% to about 40 wt.% reinforcing filler, wherein the combined weight percentage of all components does not exceed 100 wt.%, all weight percentages being based on the total weight of the monofilament, and wherein the monofilament exhibits a tensile modulus of greater than 1950 MPa when tested in accordance with ISO 527. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] Polymer filaments, fibers, and other very fine polymer extrudates can be used in many applications, including textiles. PBT is generally well suited for high-end applications because the polymer is highly flexible, elastic, and easy to process. As more sustainable materials are increasingly sought after, post-consumer recycled polymers, including post-consumer recycled (PCR) PBT, are increasingly desired for textile applications. Fibers spun from certain post-consumer recycled PBT resins typically exhibit poor mechanical properties, as evidenced by lower stress / modulus and thermal stability when compared to virgin PBT. Because modulus and stress performance are key indicators of a fiber's resistance to deformation, articles formed from such polymer fibers may exhibit less than optimal properties.

[0007] The fiber composition of the present disclosure overcomes the traditional mechanical and physical shortcomings of fibers or filaments formed using chemically upcycled PBT derived from PET. The composition of the present disclosure solves the challenges of low tensile stress and modulus of traditional recycled PBT.

[0008] Before the present compounds, compositions, articles, systems, devices, and / or methods are disclosed and described, it is to be understood that they are not limited to particular synthetic methods, unless otherwise specified, or to particular reagents, unless otherwise specified, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0009] Various combinations of elements of the present disclosure are encompassed in the present disclosure, for example combinations of elements from dependent claims that are dependent on the same independent claim.

[0010] Further, it will be understood that, unless expressly stated otherwise, it is in no way intended that any method described herein be construed as requiring that its steps be performed in a specific order. Thus, where a method claim does not actually recite the order in which its steps are to be followed, or unless the claims or specification otherwise specifically state that the steps are limited to a specific order, no order is intended to be inferred in any respect. This applies to any possible non-express basis for interpretation, including logical considerations regarding the sequence of steps or the flow of operations; the plain meaning derived from grammatical constructions and punctuation; and the number or type of embodiments described herein. filament

[0011] An embodiment of the present disclosure relates to a composite comprising a thermoplastic polymer component (including polyester) and a filler. The thermoplastic polymer component may comprise any suitable thermoplastic polymer. Examples include, but are not limited to, polycarbonate, polyetherimide, liquid crystal polymer, polyamide, polyimide, polyester, copolymers thereof, blends thereof, or combinations thereof. In a specific example, the polymer component is a chemically recycled poly(butylene terephthalate) named iQ PBT, which is derived from chemically upcycled (or post-consumer recycled) PET. Fibers formed from iQ PBT provide desirable modulus, stress at break, and elongation at break, providing environmentally friendly benefits.

[0012] Disclosed herein are chemically recycled polyester compounds filled with fillers suitable for spun fiber applications. The fillers can help the compounds achieve higher fiber modulus and strength. Suitable fillers may include fine talc, carbon fillers or fibers, glass fibers, among other organic and inorganic fillers.

[0013] The disclosed fiber compositions can be used to form fibers or filaments or single fibers or monofilaments that can have a diameter (cross-sectional dimension) of about 1 micron to about 10 mm. Micron and submicron fibers can be formed by methods known in the art. Such methods include melt spinning, spunbonding, and meltblowing. An embodiment of the present disclosure can feature a fiber or filament formed through a melt spinning process. For example, the included composition can be melt spun through a spinneret to produce multiple filaments or monofilaments. Polymer Resins

[0014] In various embodiments, the composite can comprise a thermoplastic or thermosetting resin. Thermoplastic resins can comprise polypropylene, polyethylene, ethylene-based copolymers, polyamides, polycarbonates, polyesters, polyoxymethylene (POM), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycyclohexylene dimethylene terephthalate (PCT), liquid crystal polymers (LCP), polyphenylene sulfide (PPS), polyphenylene ether (PPE), polyphenylene oxide-polystyrene blends, polystyrene, high impact modified polystyrene, acrylonitrile-butadiene-styrene (ABS) terpolymers, acrylic polymers, polyetherimides (PEI), polyurethanes, polyetheretherketones (PEEK), polylactic acid (PLA)-based polymers, polyethersulfones (PES), and combinations thereof. Thermoplastic resins can also include thermoplastic elastomers, such as polyamide-based and polyester-based elastomers. The base substrate can also comprise blends and / or other types of combinations of the above resins. In various embodiments, the composite can also comprise a thermosetting polymer. Suitable thermosetting resins can include phenolic resins, urea resins, melamine-formaldehyde resins, urea-formaldehyde latex, xylene resins, diallyl phthalate resins, epoxy resins, aniline resins, furan resins, polyurethanes, or combinations thereof.

[0015] In various aspects of the present disclosure, the thermoplastic resin can comprise a polyester. For example, the thermoplastic resin can comprise a polyalkylene ester (polyester), such as a polyalkylene terephthalate polymer.

[0016] Polyesters are represented by the following formula (A): [ka] where T is the residue derived from terephthalic acid or its chemical equivalents, and D is the residue derived from the polymerization of ethylene glycol, butylene diol, specifically 1,4-butane diol, or their chemical equivalents. Chemical equivalents of the diacids include dialkyl esters, such as dimethyl esters, diaryl esters, anhydrides, salts, acid chlorides, acid bromides, and the like. Chemical equivalents of ethylene diol and butylene diol include esters, such as dialkyl esters, diaryl esters, and the like. In addition to the units derived from terephthalic acid or its chemical equivalents, and ethylene glycol or butylene diol, specifically 1,4-butane diol or its chemical equivalents, other T and / or D units can be present in the polyester, provided that the type or amount of such units does not significantly adversely affect the desired properties of the thermoplastic composition. The poly(alkylene arylates) can have a polyester structure according to formula (A), where T comprises groups derived from aromatic dicarboxylates, cycloaliphatic dicarboxylic acids, or derivatives thereof.

[0017] Examples of specifically useful T groups include, but are not limited to, 1,2-, 1,3-, and 1,4-phenylene; 1,4- and 1,5-naphthylenes; cis- or trans-1,4-cyclohexylene; and the like. Specifically, when T is 1,4-phenylene, the poly(alkylene arylate) is a poly(alkylene terephthalate). In addition, for poly(alkylene arylate), specifically useful alkylene groups D include, for example, ethylene, 1,4-butylene, and bis-(alkylene disubstituted cyclohexane), including cis- and / or trans-1,4-(cyclohexylene)dimethylene.

[0018] Examples of polyalkylene terephthalates include polyethylene terephthalate (PET), poly(1,4-butylene terephthalate) (PBT), and poly(propylene terephthalate) (PPT). Also useful are poly(alkylene naphthoates), such as poly(ethylene naphthanoate) (PEN), poly(butylene naphthanoate) (PBN). A useful poly(cycloalkylene diester) is poly(cyclohexane dimethylene terephthalate) (PCT). Combinations comprising at least one of the foregoing polyesters may also be used.

[0019] Copolymers containing alkylene terephthalate repeating ester units with other ester groups may also be useful. Useful ester units include various alkylene terephthalate units, which can be present in the polymer chain as individual units or as blocks of poly(alkylene terephthalates). Specific examples of such copolymers include poly(cyclohexanedimethylene terephthalate)-co-poly(ethylene terephthalate), abbreviated as PETG when the polymer comprises 50 mol% or more of poly(ethylene terephthalate), and PCTG when the polymer comprises 50 mol% or more of poly(1,4-cyclohexanedimethylene terephthalate). Poly(cycloalkylene diesters) may also include poly(alkylene cyclohexane dicarboxylates). Specific examples of these include those of formula (B): [ka] Poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate) (PCCD) having repeating units of 2is a 1,4-cyclohexanedimethylene group derived from 1,4-cyclohexanedimethanol, and T is a cyclohexane ring derived from cyclohexanedicarboxylate or its chemical equivalent, and may comprise a cis isomer, a trans isomer, or a combination comprising at least one of the foregoing isomers.

[0020] In another embodiment, the composition may further comprise a poly(1,4-butylene terephthalate) or "PBT" resin. PBT may be obtained by polymerizing a glycol component consisting of at least 70 mol%, preferably at least 80 mol%, tetramethylene glycol, and an acid or ester component consisting of at least 70 mol%, preferably at least 80 mol%, terephthalic acid and / or its polyester-forming derivatives. Commercially available examples of PBT include those available under the trade names VALOX™ 315, VALOX™ 195, and VALOX™ 176, which are manufactured by SABIC™ and have an intrinsic viscosity IV of 0.1 deciliters per gram (dl / g) to about 2.0 dl / g (or 0.1 dl / g to 2 dl / g) measured in a 60:40 phenol / tetrachloroethane mixture or similar solvent at 23 degrees Celsius (°C) to 30°C. In one embodiment, the PBT resin has an intrinsic viscosity of 0.1 dl / g to 1.4 dl / g (or about 0.1 dl / g to about 1.4 dl / g), specifically 0.5 dl / g to 1.3 dl / g (or about 0.5 dl / g to about 1.3 dl / g). PBT with low intrinsic viscosity may have an intrinsic viscosity of less than 1 dl / g, less than 0.9 dl / g, or less than 0.8 dl / g. PBT with high intrinsic viscosity may have an intrinsic viscosity of greater than 1 dl / g, or greater than 1 dl / g, or from about 1 dl / g to about 1.4 dl / g, according to certain embodiments of the present disclosure. Intrinsic viscosity may be measured using a capillary rheometer in accordance with GB / T14190-2008.

[0021] The compositions of the present disclosure comprise chemically upcycled polybutylene terephthalate (PBT) derived from post-consumer recycled (PCR) polyester. In a specific embodiment, the PBT component can be derived from polyethylene terephthalate (PET). Thus, the polyester can comprise a PBT component derived from PET. The PBT component derived from a PCR polymer (such as PCR PET) can be formed according to conventional methods and can include certain PBT plastics available from SABIC™.

[0022] In certain embodiments, chemically upcycled PBT may be derived from polyethylene terephthalate. For example, upcycled PBT may be derived from a process of first depolymerizing PET and then repolymerizing the monomer to PBT through transesterification. Compositions of the present disclosure comprising chemically upcycled PBT (rPBT) can be used with some limitations (e.g., color, melting point T m Upcycled PBT may also be referred to herein as post-consumer recycled PBT.

[0023] In certain embodiments, the fiber composition may include about 1 wt.% to about 99.9 wt.% of a chemically upcycled PBT component. The chemically upcycled PBT component may be formed from monomers derived from PCR PET. In some embodiments, the chemically recycled PBT resin is obtained through polymerization of about 60% BHET monomer and about 40% BDO monomer derived from post-consumer recycled PET waste.

[0024] The post-consumer recycled or post-industrial recycled based component is specifically contemplated to be "up-cycled" or "upcycled" polybutylene terephthalate (PBT) polymer. The term "up-cycled" refers to a process in which post-consumer recycled or post-industrial recycled polyethylene terephthalate (rPET) is chemically converted back into monomers such as the terephthalate-containing monomers bis(2-hydroxyethyl) terephthalate (BHET) and ethylene glycol (EG). BHET is then polymerized with butanediol (BDO) to produce PBT (or chemically upcycled PBT, referred to herein as rPBT).

[0025] Commercial examples of upcycled PBT include those available under the trade name ELCRIN™ iQ Resin manufactured by SABIC™. PBT can be derived from a poly(ethylene terephthalate) component by any method including depolymerizing the poly(ethylene terephthalate) component and polymerizing the depolymerized poly(ethylene terephthalate) component with 1,4 butanediol to provide a PET-derived PBT. For example, a PET-derived poly(butylene terephthalate) component can be obtained by depolymerizing poly(ethylene terephthalate) and / or poly(ethylene terephthalate) copolymers with a 1,4 butanediol component at a temperature of 180° C. to 230° C. under stirring and in the presence of a catalyst component at a pressure that is at least atmospheric pressure at elevated temperature and in an inert atmosphere to produce oligomers containing ethylene terephthalate moieties, oligomers containing ethylene isophthalate moieties, oligomers containing diethylene terephthalate moieties, oligomers containing diethylene iso ... agitating the molten mixture at subatmospheric pressure and raising the temperature of the molten mixture to an elevated temperature under conditions sufficient to form a PET-derived PBT containing at least one residue derived from a poly(ethylene terephthalate) component.

[0026] PET may be described as "post-consumer recycled PET", or "recycled PET", or "post-industrial recycled PET". The PET from which the chemically upcycled PBT is derived may be in any form suitable for this disclosure. Generally, the PET component may include recycled (scrap) PET in the form of flakes, powder / chips, films, or pellets. Prior to use, PET is generally processed to remove paper, adhesives, polyolefins such as polypropylene, polyvinyl chloride (PVC), nylon, polylactic acid, and other impurities. The PET component may also include non-waste PET in the form of flakes, chips, or pellets. In this way, PET that would normally be deposited in landfills can now be used productively and effectively. PCR PET may be recovered from post-consumer sources, including, but not limited to, waste from home appliances, such as televisions, air conditioners, washing machines, refrigerators, and the like. In one embodiment, the PET component may also include other polyesters. The PET component may also include polyester copolymers. Examples of such materials include polyalkylene terephthalates that can be selected from polyethylene terephthalate, polycyclohexane terephthalate, copolyesters of terephthalic acid esters with comonomers containing cyclohexyl dimethanol and ethylene glycol, copolyesters of terephthalic acid with comonomers containing cyclohexyl dimethanol and ethylene glycol, polybutylene terephthalate, polyxylylene terephthalate, polydianol terephthalates, polybutylene terephthalate, polytrimethylene terephthalate, polyester naphthalates, and combinations thereof.

[0027] Thus, as used herein, chemically upcycled PBT may comprise at least one impurity not present in a corresponding substantially similar or identical virgin PBT. As used herein, virgin PBT refers to PBT derived from a petrochemical source. Virgin PBT does not include recycled PBT or recycled PBT content. For example, virgin PBT is derived from monomers. Thus, chemically upcycled PBT components derived from PCR PET may comprise materials such as polyethylene terephthalate residues, e.g., ethylene glycol groups and isophthalic acid groups. These components are not present in "virgin" or monomer-based PBT. Thus, chemically upcycled PBT may be distinguished from virgin PBT by the inclusion of at least 1 wt.% EG (ethylene glycol) units and at least 0.5% DEG (or up to a total of 3.5% comonomers), or isophthalic acid units, in the recycled PBT molecular chain. However, virgin PBT resin may only have terephthalic acid (TPA) and BDO monomers.

[0028] The amount of ethylene glycol, diethylene glycol, and isophthalic groups in the polymer backbone of the chemically recycled PBT component can vary. The PBT component derived from PET typically contains isophthalic acid groups in an amount that is at least 0.1 mol % and can range from 0 mol % or 0.1 mol % to 10 mol % (0 wt.% or 0.07 wt.% to 7 wt.%). The PBT component derived from PET typically contains ethylene glycol in an amount that is at least 0.1 mol % and can range from 0.1 mol % to 10 mol % (0.02 wt.% to 2 wt.%). In one embodiment, the PBT component derived from PET has an ethylene glycol content of greater than 0.85 wt.%. The chemically upcycled PBT component can also contain diethylene glycol in an amount ranging from 0.1 mol % to 10 mol % (0.04 wt.% to 4 wt.%). The amount of butanediol groups is generally about 98 mole %, and in some embodiments can vary from 95 mole % to 99.8 mole %. The amount of terephthalic acid groups is generally about 98 mole %, and in some embodiments can vary from 90 mole % to 99.9 mole %.

[0029] Unless otherwise specified, the total molar amount of isophthalic acid groups and / or terephthalic acid groups is based on the total moles of diacids / diesters in the composition.Unless otherwise specified, the total molar amount of butanediol groups, ethylene glycol groups, and diethylene glycol groups is based on the total moles of diols in the composition.The weight percent measurements above are based on the way terephthalic acid groups, isophthalic acid groups, ethylene glycol groups, and diethylene glycol groups are defined herein.

[0030] The total amount of polyethylene terephthalate component residue material in the chemically upcycled polybutylene random copolymer can vary. Illustratively, the mixture can be in an amount ranging from 1.8 wt.% to 2.5 wt.%, or 0.5 wt.% to 2 wt.%, or 1 wt.% to 4 wt.%. The ethylene glycol, diethylene glycol, and cyclohexanedimethanol groups can be present individually or in combination in an amount ranging from 0.1 mol % to 10 mol % based on 100 mol % glycol in the molding composition. The isophthalic acid groups can be present in an amount ranging from 0.1 mol % to 10 mol % based on 100 mol % diacid / diester in the molding composition.

[0031] It has been found that when it is desired to produce a polybutylene terephthalate copolymer having a melting point Tm of at least 200° C., the total amount of diethylene glycol groups, ethylene glycol groups, and isophthalic acid groups is desirably within a certain range. Thus, in one embodiment, the total amount of diethylene glycol groups, ethylene glycol groups, and isophthalic acid groups in the polybutylene terephthalate component derived from PET is greater than 0 equivalents and not more than 23 equivalents relative to the total of 100 equivalents of diol groups and 100 equivalents of diacid groups in the polybutylene terephthalate random copolymer derived from PET. In another preferred embodiment, the total amount of isophthalic acid groups, ethylene glycol groups, and diethylene glycol groups ranges from 3 equivalents to not more than 23 equivalents relative to the total of 100 equivalents of diol groups and 100 equivalents of diacid groups in the polybutylene terephthalate copolymer derived from PET. In another preferred embodiment, the total amount of isophthalic acid groups, ethylene glycol groups, and diethylene glycol groups ranges from 3 equivalents to 10 equivalents or less, relative to the total of 100 equivalents of diol groups and 100 equivalents of diacid groups in the polybutylene terephthalate random copolymer derived from PET. In another preferred embodiment, the total amount of isophthalic acid groups, ethylene glycol groups, and diethylene glycol groups ranges from 10 equivalents to 23 equivalents or less, relative to the total of 100 equivalents of diol groups and 100 equivalents of diacid groups in the polybutylene terephthalate random copolymer derived from PET. In one embodiment, diethylene glycol, ethylene glycol, and / or isophthalic acid can be added during the process, which allows the user to have a system to create compositions with different properties.

[0032] The total ethylene glycol group, isophthalic acid group, and diethylene glycol group can be varied according to the application and the needs of the user. In one embodiment, the composition can have a total monomer content selected from the group consisting of ethylene glycol group, isophthalic acid group, and diethylene glycol group in an amount ranging from more than 0 equivalents to 17 equivalents relative to the total of 100 equivalents of diol group and 100 equivalents of diacid group in the polybutylene terephthalate random copolymer derived from PET. Advantageously, such a composition can maintain useful properties, such as a deflection temperature under load higher than 180°C.

[0033] It has also been found that the total amount of inorganic residues derived from polyethylene terephthalate can be present from greater than 0 ppm up to 1000 ppm. Examples of such inorganic residues can be selected from the group consisting of antimony-containing compounds, germanium-containing compounds, titanium-containing compounds, cobalt-containing compounds, tin-containing compounds, aluminum, aluminum salts, alkaline earth metal salts, alkali salts such as calcium, magnesium, sodium, and potassium salts, phosphorus-containing compounds and anions, sulfur-containing compounds and anions, and combinations thereof. In another embodiment, the amount of inorganic residues can range from 250 ppm to 1000 ppm. In another embodiment, the amount of inorganic residues can range from 500 ppm to 1000 ppm.

[0034] As described herein, the composition may comprise from about 40 wt.% to about 99 wt.% of the polyalkylene polymer. In further examples, the composition may comprise from about 50 wt.% to about 99 wt.% of the polyalkylene polymer, or from about 40 wt.% to about 99 wt.% of the polyalkylene polymer, or from about 55 wt.% to about 99 wt.% of the polyalkylene polymer, or from about 60 wt.% to about 99 wt.% of the polyalkylene polymer, or from about 70 wt.% to about 99 wt.% of the polyalkylene polymer, or from about 40 wt.% to about 99 wt.% of the polyalkylene polymer, or from about 55 wt.% to about 99 wt.% of the polyalkylene polymer, or from about 60 wt.% to about 95 wt.% of the polyalkylene polymer, or from about 75 wt.% to about 99 wt.%.

[0035] In still further embodiments, the disclosed compositions comprise from about 50 wt.% to about 99.99 wt.% upcycled PBT resin, or from about 40 wt.% to about 99 wt.% upcycled PBT resin, or from about 55 wt.% to about 99 wt.% upcycled PBT resin, or from about 60 wt.% to about 99 wt.% upcycled PBT resin, or from about 70 wt.% to about 99 wt.% upcycled PBT resin, or from about 40 wt.% to about 99 wt.% upcycled PBT resin, or from about 55 wt.% to about 99 wt.% upcycled PBT resin, or from about 60 wt.% to about 99 wt.% upcycled PBT resin, or from about 75 wt.% to about 99.98 wt.% upcycled PBT resin. In various embodiments, the composite comprises a blend of thermoplastic resins, such as a blend of suitable upcycled PBT resins.

[0036] In various embodiments, there may be a certain amount of low I.V. PBT resin (or upcycled PBT resin) compared to the amount of high I.V. PBT resin (or upcycled PBT resin). The composition may comprise about 50 wt.% to about 99 wt.%, about 60 wt.% to about 95 wt.%, or about 65 wt.% to about 90 wt.%, about 65 wt.% to about 85 wt.% of high IV PBT resin or upcycled / post-consumer recycled PBT resin. In a further example, the composition may comprise about 1 wt.% to about 30 wt.% of low IV PBT resin or upcycled / post-consumer recycled PBT resin.

[0037] Reinforcing Fillers

[0038] The compositions of the present invention may comprise inorganic fillers or reinforcing agents. The specific composition of the filler, if present, may vary, provided that the filler is chemically compatible with the remaining components of the thermoplastic composition. Suitable fillers or reinforcing agents include, for example, granite, clay, feldspar, quartz, quartzite, perlite, tripoly, diatomaceous earth, aluminum silicate (mullite), synthetic calcium silicate, fused silica, fumed silica, sand, boron nitride powder, boron silicate powder, calcium sulfate, calcium carbonates (chalk, limestone, marble, synthetic precipitated calcium carbonate, etc.), talc (including fibrous, modular, acicular, and lamellar talc), wollastonite, hollow or solid glass spheres, silicate spheres, cenospheres, aluminosilicates or (almospheres), kaolin, whiskers of silicon carbide, alumina, boron carbide, iron, nickel, or copper, continuous and chopped carbon or glass fibers, molybdenum sulfide, zinc sulfide, barium titanate, barium ferrite, barium sulfate, barite, bipyrrolite, bismuth oxide ... Examples of fillers include titanium oxide, aluminum oxide, magnesium oxide, particulate or fibrous aluminum, bronze, zinc, copper, or nickel, glass flakes, flaked silicon carbide, flaked aluminum diboride, flaked aluminum, steel flakes, natural fillers such as wood flour, fibrous cellulose, cotton, sisal, jute, starch, lignin, crushed nut shells, or rice husks, reinforcing organic fibrous fillers such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides, aromatic polyimides, polyetherimides, polytetrafluoroethylene, and poly(vinyl alcohol), as well as combinations comprising at least one of the above fillers or reinforcing agents. Fillers and reinforcing agents may be coated or surface treated, for example with silane, to improve adhesion and dispersibility with the polymer matrix. Fillers can generally be used in amounts of 1 part by weight to 200 parts by weight based on 100 parts by weight of the total composition.

[0039] In some embodiments, the fiber composition may comprise a mineral filler. Examples of mineral fillers include talc, calcium carbonate, dolomite, wollastonite, barium sulfate, silica, kaolin, feldspar, barite, or the like, or a combination comprising at least one of the preceding mineral fillers. The mineral filler may have an average particle size of about 0.1 micrometer to about 20 micrometers, specifically about 0.5 micrometer to about 10 micrometers, and more specifically about 1 micrometer to about 3 micrometers. In a specific example, the reinforcing filler is a mineral filler, such as fine talc, having an average particle size D50 of less than 1.5 μm.

[0040] Suitable inorganic fillers include metal silicate and silica powders; boron-containing oxides of aluminum (Al), magnesium (Mg), or titanium (Ti); anhydrous or hydrated calcium sulfate; wollastonite; hollow and / or solid glass spheres; kaolin; single crystal metal or inorganic fibers or "whiskers"; glass fibers (including continuous fibers and chopped fibers, including flat glass fibers); sulfides of molybdenum (Mo) or zinc (Zn); barium compounds; metals and metal oxides; flake fillers; fibrous fillers; and fillers capable of forming fibers. short inorganic fibers reinforcing organic fibrous fillers formed from organic polymers (e.g., polyetheretherketone (PEEK), polyetherimide (PEI), polytetrafluoroethylene (PTFE), polyphenylene sulfide (PPS)); and fillers and reinforcing agents such as, but not limited to, granite, clay, feldspar, flue dust, phyllite, quartz, quartzite, perlite, tripoly, diatomaceous earth, carbon black, or a combination comprising at least one of the foregoing fillers or reinforcing agents. In some embodiments, the fillers can comprise inorganic materials which can include clay, titanium dioxide, asbestos fibers, silicate and silica powders, boron powders, calcium carbonates, talc, kaolin, sulfides, barium compounds, metals and metal oxides, wollastonite, glass spheres, glass fibers, flaky fillers, fibrous fillers, natural fillers and reinforcing agents, and reinforcing organic fibrous fillers. In certain embodiments, the composite can comprise glass fiber fillers. In yet further embodiments, the composite may be free or substantially free of glass fillers. In one embodiment, the composition comprises an inorganic filler selected from glass fiber, glass flake, talc, clay, granite, wollastonite, titanium dioxide, or combinations thereof. A mineral filler such as talc. In a specific embodiment, the reinforcing filler may comprise talc.

[0041] The reinforcing filler may have a particular particle size or average particle size. For example, the reinforcing filler may have an average particle size (D) of about 0.1 micrometers (μm) to about 10 μm. 50With respect to the particle size distribution, D represents the diameter of the particle, and D 50 is the diameter of the cumulative 50% point (or the diameter value of the 50% passing particle or particle at 50% in the cumulative distribution); D 10 means the diameter at the cumulative 10% point; D 90 is the diameter at the cumulative 90th percentile; and D 95 is the diameter of the cumulative 95th percentile; D 50 is also referred to as the average particle size or median diameter. Particle size distribution may be determined according to any method known in the art; for commercially available products or reagents, the particle size distribution is obtained from the manufacturer. An example of fine talc may be available from Imerys as Jetfine™ talc, e.g., Jetfine™ 3CA. In some examples, the reinforcing filler has a particle size or average particle size of about 0.5 μm to about 1.5 μm, or about 0.8 μm to about 1.3 μm. In further examples, the reinforcing filler has a D95 of about 3.0 μm to about 4 μm, or about 3.3 μm to about 3.8 μm. In specific examples, the reinforcing filler has a particle size or average particle size of about 1.1 μm and a D95 of about 3.5 μm. 95 In yet a further example, the reinforcing filler has an average particle size D of less than 1.2 μm. 50 The talc comprises finely divided talc having the formula:

[0042] In some examples, the reinforcing filler may be present in an amount of about 0.01 wt.% to about 20 wt.%, In further examples, the reinforcing filler may be present in an amount of 0.01 wt.% to about 20 wt.%, 0.05 wt.% to about 20 wt.%, or 0.1 wt.% to about 20 wt.%, or about 0.1 wt.% to about 15 wt.%, or about 0.1 wt.% to about 18 wt.%, or about 0.1 wt.% to about 10 wt.%, or about 0.1 wt.% to about 8 wt.%, or about 0.1 wt.% to about 5 wt.%, or about 0.2 wt.% to about 20 wt.%, or about 0.2 wt.% to about 15 wt.%, or about 0.2 wt.% to about 12 wt.%, or about 0.05 wt.% to about 20 wt.%, or about 0.1 wt.% to about 20 ... or may be present in an amount of from about 0.2 wt.% to about 10 wt.%, or from about 0.2 wt.% to about 8 wt.%, or from about 0.2 wt.% to about 5 wt.%, or from about 0.2 wt.% to about 3 wt.%, or from about 0.05 wt.% to about 20 wt.%, or from about 0.05 wt.% to about 15 wt.%, or from about 0.05 wt.% to about 12 wt.%, or from about 0.05 wt.% to about 10 wt.%, or from about 0.05 wt.% to about 8 wt.%, or from about 0.05 wt.% to about 5 wt.%, or from about 0.05 wt.% to about 3 wt.%. Additives

[0043] The disclosed thermoplastic compositions may comprise one or more additives conventionally used in the manufacture of molded thermoplastic parts, provided that such optional additives do not adversely affect the desired properties of the resulting composition. Mixtures of optional additives may also be used. Such additives may be mixed at a suitable time during the mixing of the components to form the composite mixture. Exemplary additives may include UV agents, UV stabilizers, heat stabilizers, antistatic agents, antimicrobial agents, anti-drip agents, radiation stabilizers, pigments, dyes, fibers, fillers, plasticizers, fibers, flame retardants, antioxidants, lubricants, wood, glass, and metals, and combinations thereof. According to certain embodiments, the polymeric compositions may maintain mechanical and dielectric performance even with high levels of fillers (e.g., more than 30 wt.% filler based on the total weight of the polymeric composition).

[0044] The composites disclosed herein may include one or more additional fillers. The fillers may be selected to provide additional impact strength and / or additional characteristics that may be based on the final selected characteristics of the polymer composition. In some embodiments, the fillers may comprise inorganic materials that may include clay, titanium dioxide, asbestos fibers, silicate and silica powders, boron powders, calcium carbonates, talc, kaolin, sulfides, barium compounds, metals and metal oxides, wollastonite, glass spheres, glass fibers, flaky fillers, fibrous fillers, natural fillers and reinforcing agents, and reinforcing organic fibrous fillers. In certain embodiments, the composites may comprise glass fiber fillers. For example, the composites may comprise about 0.01 wt.% to about 25 wt.%, about 10 wt.% to about 25 wt.%, about 15 wt.% to about 25 wt.% of glass fiber fillers based on the total weight of the composite. In yet a further aspect, the composite can be free or substantially free of glass fillers.

[0045] The thermoplastic composition may comprise an antioxidant. The antioxidant may include either a primary or secondary antioxidant. For example, antioxidants include organic phosphites such as tris(nonylphenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite, bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, distearyl pentaerythritol diphosphite, or the like; alkylated monophenols or polyphenols; alkylation reaction products of polyphenols with dienes such as tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)]methane, or the like; butylation reaction products of para-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene bisphenols; benzyl compounds; beta-(3,5-di-tert-butyl-4-hydroxyphenyl) ethers; alkylated ... esters of beta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with monohydric or polyhydric alcohols; esters of thioalkyl or thioaryl compounds such as distearyl thiopropionate, dilauryl thiopropionate, ditridecyl thiodipropionate, octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, or the like; amides such as beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid or the like, or a combination comprising at least one of the foregoing antioxidants. Antioxidants may generally be used in amounts of 0.01 to 0.5 parts by weight based on 100 parts by weight of the total composition, excluding any fillers.

[0046] In a specific embodiment, the antioxidant is a hindered phenol, such as Irganox™ 1010 available from BASF. The hindered phenol may be of the type that contains a sterically hindered phenol group, particularly a t-butyl group in the ortho position to the phenolic OH group. Examples of such compounds are numerous. Examples are tetrakis(methylene-3-(-3',5'-di-tert-butyl-4'-hydroxyphenyl)-propionate)methane; octadecyl-3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate; 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene; 2,2'-thiodiethylbis(3-(3,5-di-tert-butyl-4-hydroxyphenyl))propionate; octadecyl-3,5-di-tert-butyl-4-hydroxyhydrocinnamate, and mixtures of any of the foregoing. In some instances, octadecyl-3,5-di-tert-butyl-4-hydroxyhydrocinnamate, available commercially as Irganox™ 1076, is useful. Further examples of the above-mentioned phenolic antioxidants include known compounds such as monophenolic compounds such as 2,6-di-t-butyl-4-ethylphenol, and octadecyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, 2,2'-methylene-bis-(4-methyl-6-t-butylphenol), 2,2'-methylene-bis-(4-ethyl-6-t-butylphenol), and 4,4'-butylidenebis-(3-methyl-t-butylphenol). and bisphenol-based compounds such as 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)butane, tetrakis[methylene-3-(3',5'-di-t-butyl-4'-hydroxyphenyl)propionate]methane, bis[3,3'-bis(4'-hydroxy-3'-t-butylphenyl)butyric acid] glycol ester, and the like. Each of these can be used in an amount of 0.001 wt.% to 2.0 wt.%, preferably 0.05 wt.% to 1.0 wt.%, based on the composition.

[0047] In various embodiments, the thermoplastic composition can comprise a mold release agent. Exemplary mold release agents can include, for example, metal stearates, stearyl stearate, pentaerythritol tetrastearate, beeswax, montan wax, paraffin wax, or the like, or a combination comprising at least one of the foregoing mold release agents. Mold release agents are generally used in amounts of about 0.1 to about 1.0 parts by weight based on 100 parts by weight of the total composition, excluding any fillers.

[0048] In one embodiment, the thermoplastic composition may comprise a heat stabilizer. By way of example, the heat stabilizer may include organic phosphites such as triphenyl phosphite, tris-(2,6-dimethylphenyl) phosphite, tris-(mixture of mono- and di-nonylphenyl) phosphite, or the like; phosphonates such as dimethylbenzene phosphonate, or the like; phosphates such as trimethyl phosphate, or the like, or a combination comprising at least one of the preceding heat stabilizers. The heat stabilizer may generally be used in an amount of 0.01 to 0.5 parts by weight based on 100 parts by weight of the total composition, excluding any fillers.

[0049] In a further embodiment, a light stabilizer can be present in the thermoplastic composition. Exemplary light stabilizers can include, for example, benzotriazoles such as 2-(2-hydroxy-5-methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole, and 2-hydroxy-4-n-octoxybenzophenone, or the like, or a combination comprising at least one of the foregoing light stabilizers. The light stabilizer can generally be used in an amount of about 0.1 parts by weight to about 1.0 parts by weight based on 100 parts by weight of the total composition, excluding any fillers. The thermoplastic composition can also comprise a plasticizer. For example, the plasticizer can include phthalates such as dioctyl-4,5-epoxy-hexahydrophthalate, tris-(octoxycarbonylethyl)isocyanurate, tristearin, epoxidized soybean oil, or the like, or a combination comprising at least one of the foregoing plasticizers. Plasticizers are generally used in amounts of about 0.5 to about 3.0 parts by weight, based on 100 parts by weight of the total composition, excluding any fillers.

[0050] Ultraviolet (UV) absorbers can also be present in the disclosed thermoplastic compositions. Exemplary UV absorbers include, for example, hydroxybenzophenones; hydroxybenzotriazoles; hydroxybenzotriazines; cyanoacrylates; oxanilides; benzoxazinones; 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (CYASORB™ 5411); 2-hydroxy-4-n-octyloxybenzophenone (CYASORB™ 531); 2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)-phenol (CYASORB™ 1164); 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) (CYASORB™ 1164); UV-3638; 1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane (UVINUL™ 3030); 2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one); 1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane; nanosized inorganic materials such as titanium oxide, cerium oxide, and zinc oxide, all having a particle size of less than 100 nanometers; and the like or combinations comprising at least one of the foregoing UV absorbers. UV absorbers are generally used in amounts of 0.01 to 3.0 parts by weight based on 100 parts by weight of the total composition, excluding any fillers.

[0051] The thermoplastic composition may further comprise a lubricant. For example, the lubricant may be a fatty acid ester, such as alkyl stearyl esters, for example, methyl stearate or the like; a mixture of methyl stearate with hydrophilic and hydrophobic surfactants, such as polyethylene glycol polymers, polypropylene glycol polymers, and copolymers thereof, for example, methyl stearate and polyethylene-polypropylene glycol copolymer in a suitable solvent; or a combination comprising at least one of the above lubricants. The lubricant may generally be used in an amount of about 0.1 parts by weight to about 5 parts by weight based on 100 parts by weight of the total composition, excluding any fillers.

[0052] Anti-drip agents can also be used in the composition, such as fibril-forming or non-fibril-forming fluoropolymers, such as polytetrafluoroethylene (PTFE). Anti-drip agents can be encapsulated by a hard polymer, such as styrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is known as TSAN. In one example, TSAN can comprise 50 wt.% PTFE and 50 wt.% SAN based on the total weight of the encapsulated fluoropolymer. SAN can comprise, for example, 75 wt.% styrene and 25 wt.% acrylonitrile based on the total weight of the copolymer. Anti-drip agents, such as TSAN, can be used in amounts of 0.1 to 10 parts by weight based on 100 parts by weight of the total composition, excluding any fillers.

[0053] In one example, the disclosed composition can comprise an impact modifier. The impact modifier can be a chemically reactive impact modifier. By definition, the chemically reactive impact modifier can have at least one reactive group such that when the impact modifier is added to a polymer composition, it improves the impact properties (expressed as IZOD impact strength value) of the composition. In some examples, the chemically reactive impact modifier can be an ethylene copolymer having reactive functional groups selected from, but not limited to, anhydride, carboxyl, hydroxyl, and epoxy.

[0054] In a further aspect of the present disclosure, the composition may comprise a rubbery impact modifier. The rubbery impact modifier may be a polymeric material that is capable of substantially recovering its shape and size at room temperature after removal of force. However, it is desirable for the rubbery impact modifier to have a glass transition temperature that is typically less than 0° C. In certain aspects, the glass transition temperature (T g ) can be less than -5°C, less than -10°C, less than -15°C, and T less than -30°C g typically provide better performance. Exemplary rubbery impact modifiers include, for example, functionalized polyolefin ethylene-acrylate terpolymers, such as ethylene-acrylic esters-maleic anhydride (MAH) or glycidyl methacrylate (GMA). The functionalized rubbery polymer may optionally contain repeat units in its backbone derived from anhydride group-containing monomers, such as maleic anhydride. In another scenario, the functionalized rubbery polymer may contain anhydride moieties that are grafted to the polymer in a post-polymerization step.

[0055] In one embodiment, a suitable impact modifier may include an epoxy-functional block copolymer. The epoxy-functional block copolymer may be 2-20It may comprise units derived from olefins and units derived from glycidyl (meth)acrylate. Exemplary olefins include ethylene, propylene, butylene, and the like. The olefin units may be present in the copolymer in the form of blocks, such as blocks of polyethylene, polypropylene, polybutylene, and the like. It is also possible to use mixtures of olefins, i.e., blocks containing a mixture of ethylene and propylene units, or blocks of polyethylene with blocks of polypropylene.

[0056] In addition to the glycidyl (meth)acrylate units, the epoxy-functional block copolymer may contain additional units, such as C 1-4 It may further comprise alkyl(meth)acrylate units. In one embodiment, the impact modifier is a terpolymer and comprises a polyethylene block, a methyl acrylate block, and a glycidyl methacrylate block. A specific impact modifier is a copolymer or terpolymer comprising ethylene, glycidyl methacrylate (GMA), and methyl acrylate units. Suitable impact modifiers include ethylene-methyl acrylate glycidyl methacrylate terpolymers comprising 8 wt.% or about 8 wt.% glycidyl methacrylate units available from Arkema under the trade name LOTADER™ AX8900. Another epoxy-functional block copolymer that can be used in the composition includes ethylene acrylate, such as an ethylene-ethyl acrylate copolymer having an ethyl acrylate content of less than 20%, available from Rohm and Haas (Dow Chemical) under the trade name Paraloid™ EXL-3330. It will be appreciated that combinations of impact modifiers may be used.

[0057] In some embodiments, the impact modifier may be present in an amount of from greater than 0 wt.% to 10 wt.%, or from greater than 0 wt.% to about 10 wt.%. In further embodiments, the impact modifier is present in an amount of from 0.01 wt.% to 8 wt.%, or from about 0.01 wt.% to about 8 wt.%, or from 0.01 wt.% to 7 wt.%, or from about 0.01 wt.% to about 7 wt.%, 0.01 wt.% to about 6 wt.%, or from about 0.01 wt.% to about 6 wt.%, or from 2 wt.% to 8 wt.%, or from about 2 wt.% to about 8 wt.%, or from 3 wt.% to 7 wt.%, or from about 3 wt.% to about 7 wt.%. Properties and Items

[0058] In certain embodiments, the disclosed fiber compositions may exhibit certain properties when configured as fibers or filaments or when formed into fibers or filaments. The disclosed compositions may exhibit improved modulus when compared to a reference composition comprising virgin PBT and in the absence of upcycled PBT and / or talc. When formed into fibers, the disclosed compositions exhibit improved modulus, and stress and strain when compared to a reference composition comprising virgin PBT and in the absence of upcycled PBT and / or fine talc. The disclosed fiber compositions may survive melt processing to form fibers or monofilaments while also maintaining structural properties. For example, the disclosed compositions form fibers that exhibit a tensile modulus of greater than 1950 MPa or greater than 1960 MPa when tested according to ISO 527 when compared to a reference formulation of a fiber composition with the same reinforcing filler but with chemically upcycled PBT. In a further example, the disclosed compositions form fibers that exhibit a tensile modulus of greater than 265 σ. b , and form fibers that exhibit a breaking strain or breaking elongation of less than 75%.

[0059] Advantageously, the disclosed fiber compositions provide filaments that exhibit similar performance properties as filaments formed from molding compositions containing monomeric (or virgin) PBT, despite the use of chemically upcycled PBT (structurally different from virgin PBT). Thus, the disclosed compositions may provide an efficient means of using underutilized scrap PET in PBT thermoplastic compositions, making efficient use of post-consumer or post-industrial streams. Additionally, the disclosed fiber compositions may be environmentally desirable and contribute to the conservation of non-renewable resources. Surprisingly, monofilaments melt-spun from the disclosed fiber compositions may exhibit improved tensile properties when compared to fibers melt-spun from a reference composition comprising reinforcing fillers and virgin PBT.

[0060] In various aspects, the present disclosure relates to an article comprising the composition herein. Aspects of the present disclosure include an article comprising the fiber composition, such as one or more fibers or filaments. Yet another embodiment of the present disclosure is an article (e.g., a fabric, or a filament) comprising the fiber composition. The fiber composition can be used to form monofilaments by known processes such as melt spinning. Monofilaments of the disclosed compositions can be useful for making fabrics or other textiles. Moreover, the advantageous properties of the compositions disclosed herein can make them suitable for a range of applications. Method for Making a Fiber Composition

[0061] Aspects of the present disclosure further relate to methods of making fibrous compositions comprising recycled PBT and reinforcing fillers. In many embodiments, the compositions can be prepared according to a variety of methods. The compositions of the present disclosure can be blended, compounded, or otherwise combined with the aforementioned components by a variety of methods, including intimately mixing the materials with any additional additives desired in the formulation. Melt processing methods can be used since melt mixing equipment is available in commercial polymer processing facilities. In various further embodiments, the equipment used in such melt processing methods can include, but is not limited to, co-rotating and counter-rotating extruders, single screw extruders, co-kneaders, disk pack processors, and various other types of extrusion equipment. In further embodiments, the extruder is a twin screw extruder. In various further embodiments, the compositions can be processed in the extruder at temperatures of about 180°C to about 350°C, particularly 250°C to 300°C.

[0062] The method may further comprise processing the composition to provide a filament or fiber of a desired diameter. Melt spinning, melt blowing, spunbonding, and filament melt fabrication (FFF) processes are examples of methods for forming a filament or fiber comprising the composition. Fibers, or filaments, or monofilaments, may be formed by a melt spinning process. Such filaments may be formed by extruding a molten thermoplastic material, or by co-extruding a plurality of molten thermoplastic materials as filaments from a plurality of thin (typically circular) capillaries in a spinneret. The diameter of the capillary is selected in view of the desired fiber cross-sectional dimension (e.g., diameter). As the filament exits the capillary, the diameter of the extruded filament is typically rapidly reduced, for example, by non-eductive or eductive fluid withdrawal, or other known melt spinning mechanisms. Further examples of producing spunbond nonwoven webs can be found in U.S. Patent Nos. 4,340,563; 3,692,618; 3,338,992; 3,341,394; 3,276,944; 3,502,538; 3,502,763; and 3,542,615.

[0063] A method of forming a polymer fiber or a plurality of polymer fibers may comprise forming a molten mixture comprising about 60 wt.% to about 99 wt.% of a polymeric resin and about 0.1 wt.% to about 40 wt.% of a reinforcing filler. The molten mixture may be extruded through a spinneret to form a filament or a plurality of filaments. The filament or a plurality of filaments may be allowed to solidify to form a fiber or a plurality of polymer fibers. Each of the plurality of polymer fibers may exhibit a tensile modulus of greater than 1950 megapascals (MPa) when tested in accordance with ISO 527.

[0064] Various combinations of elements of the present disclosure are encompassed in the present disclosure, for example combinations of elements from dependent claims that are dependent on the same independent claim. definition

[0065] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used herein and in the claims, the term "comprising" can include "consisting of" and "consisting essentially of" embodiments. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In this specification and in the claims that follow, reference will be made to several terms that are intended to be defined herein.

[0066] As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a thermoplastic polymer component" includes a mixture of two or more thermoplastic polymer components. As used herein, the term "combination" includes blends, mixtures, alloys, reaction products, and the like.

[0067] In one embodiment, "substantially free of" can be less than about 0.5 weight percent (wt.%). In another embodiment, substantially free can be less than about 0.1 wt.%. In another embodiment, substantially free can be less than about 0.01 wt.%. In yet another embodiment, substantially free can be less than about 100 ppm. In yet another embodiment, substantially free can refer to amounts below detectable levels, if any. For example, a carbon fiber filler or composite can be free or substantially free of carbon nanotubes, carbon platelets, or carbon powders.

[0068] Disclosed are the components used to prepare the disclosed compositions, as well as the compositions themselves used within the methods disclosed herein. These and other materials are disclosed herein, and when combinations, subsets, interactions, groups, etc. of these materials are disclosed, it is understood that each of the various individual and collective combinations and permutations of these compounds are specifically contemplated and described herein, although they may not be expressly disclosed as specifically referring to each of them. For example, when a particular compound is disclosed and discussed, and multiple modifications that can be made to multiple molecules that include the compound are discussed, what is specifically contemplated is each and every combination and permutation of the compound and modifications that are possible, unless otherwise specifically indicated to the contrary. Thus, when a class of molecules A, B, and C is disclosed, as well as a class of molecules D, E, and F, and an example of a combination molecule AD is disclosed, this means that each is individually and collectively contemplated, even if each is not individually mentioned, and the combinations AE, AF, BD, BE, BF, CD, CE, and CF are considered to be disclosed. Similarly, any subsets or combinations of these are disclosed. Thus, for example, the subgroups AE, BF, and CE may be considered to be disclosed. This concept applies to all aspects of this application, including but not limited to steps in the methods of making and using the compositions of this disclosure. Thus, where there are various additional steps that can be performed, it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the method of this disclosure.

[0069] In this specification and the appended claims, reference to parts by weight of a particular component or ingredient in a composition or article indicates the weight relationship, expressed in parts by weight, between that component or ingredient and the other components or ingredients in the composition or article. Thus, in a compound containing 2 parts by weight of component X and 5 parts by weight of component Y, X and Y are present in a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are included in the compound.

[0070] Weight percentages of components are based on the total weight of the formulation or composition in which the component is included, unless specifically stated to the contrary.

[0071] As used herein, the term "number average molecular weight" or "M n " may be used interchangeably and refers to the statistical average molecular weight of all polymer chains in a sample and has the formula:

number

[0072] As used herein, the terms “BisA,” “BPA,” or “bisphenol A” may be used interchangeably and, as used herein, have the formula: [ka] It refers to a compound having a structure represented by the following formula:

[0073] BisA may also be referred to as 4,4'-(propane-2,2-diyl)diphenol; p,p'-isopropylidenebisphenol; or 2,2-bis(4-hydroxyphenyl)propane. BisA has the CAS Registry Number 80-05-7.

[0074] As used herein, "polycarbonate" refers to an oligomer or polymer containing the residues of one or more dihydroxy compounds, such as dihydroxy aromatic compounds, joined by carbonate linkages, and is inclusive of homopolycarbonates, copolycarbonates, and (co)polyestercarbonates.

[0075] As used herein, a "virgin polymer" or "virgin resin," such as "virgin PBT," may refer to a polymer resin produced from a petrochemical feedstock, such as natural gas or crude oil.

[0076] The terms "residue" and "structural unit" as used with respect to components of a polymer are synonymous throughout this specification.

[0077] As used herein, the terms "weight percent," "wt%," and "wt.%" can be used interchangeably and refer to the weight percent of a given component based on the total weight of the composition, unless otherwise specified. That is, all wt% values ​​are based on the total weight of the composition, unless otherwise specified. It is to be understood that the sum of the wt% values ​​of all components in a disclosed composition or formulation equals 100.

[0078] Fibers, or filaments, or monofilaments, may be formed by the process of melt spinning. Such filaments may be formed by extruding a molten thermoplastic material or by co-extruding multiple molten thermoplastic materials as filaments from multiple thin (typically circular) capillaries in a spinneret. The diameter of the capillaries is selected in view of the desired fiber cross-sectional dimensions (e.g., diameter). As the filaments exit the capillaries, the diameter of the extruded filaments is typically rapidly reduced, for example, by non-extractive or extractive fluid withdrawal, or other known melt spinning mechanisms. Further examples of producing spunbond nonwoven webs can be found in U.S. Patent Nos. 4,340,563; 3,692,618; 3,338,992; 3,341,394; 3,276,944; 3,502,538; 3,502,763; and 3,542,615.

[0079] The term "meltblown fiber" or "meltblown filament" may refer to a fiber formed by extruding molten thermoplastic material as molten threads or filaments through multiple thin (typically circular) die capillaries into a high velocity gas (e.g., air) stream that attenuates the filaments of molten thermoplastic material, reducing their diameter to that of the microfiber. The meltblown fibers are then carried by the high velocity gas stream and deposited on a collection surface, forming a web of randomly dispersed meltblown fibers to form a meltblown fabric. The meltblowing process is well known and described in various patents, including U.S. Pat. No. 3,849,241.

[0080] Unless otherwise stated herein to the contrary, all testing standards are the latest standards in effect at the time of filing this application.

[0081] Each of the materials disclosed herein is commercially available and / or methods for its preparation are known to those of skill in the art.

[0082] It is understood that the compositions disclosed herein have specific functions. Disclosed herein are specific structural requirements that perform the disclosed functions, and it is understood that there are various structures that can perform the same functions associated with the disclosed structures, and that these structures typically achieve the same results.

[0083] Ranges can be expressed herein as from one value (a first value) to another value (a second value). When such a range is expressed, the range, in some embodiments, includes one or both of the first and second values. Similarly, when values ​​are expressed as approximations, it will be understood that the particular value forms another embodiment by use of the antecedent "about." It will further be understood that the endpoints of each range are significant both in relation to the other endpoint, and independently of the other endpoint. It will also be understood that there are multiple values ​​disclosed herein, and that each value is also disclosed herein as "about" that value, in addition to the particular value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. It will also be understood that each unit between two particular units is also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0084] As used herein, the terms "about" and "at or near" mean that the quantity or value in question can be the specified value, approximately the specified value, or about the specified value. As used herein, unless otherwise indicated or inferred, the value is generally understood to be a variation of ±10% of the nominal value indicated. The term is intended to convey that the equivalent results or effects described in the claims are promoted by such similar values. That is, it is understood that the amounts, sizes, formulations, parameters, and other quantities and characteristics are not and do not have to be exact, but can be approximate and / or larger or smaller as desired, reflecting tolerances, conversion factors, rounding, measurement errors, and the like, and other factors known to those skilled in the art. In general, the amounts, sizes, formulations, parameters, or other quantities or characteristics are "about" or "approximate", whether or not they are expressly defined as such. When "about" is used before a quantitative value, the parameter is also understood to include the specific quantitative value itself, unless otherwise specifically defined.

[0085] As used herein, the term "optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes both instances in which the event or circumstance occurs and instances in which the event or circumstance does not occur. For example, the phrase "optionally an additional step" means that the additional step may or may not be included, and that the description includes both methods that include and methods that do not include the additional step.

[0086] Disclosed are the components used to prepare the disclosed compositions, as well as the compositions themselves used within the methods disclosed herein. These and other materials are disclosed herein, and when combinations, subsets, interactions, groups, etc. of these materials are disclosed, it is understood that each of the various individual and collective combinations and permutations of these compounds are specifically contemplated and described herein, although they may not be expressly disclosed as specifically referring to each of them. For example, when a particular compound is disclosed and discussed, and multiple modifications that can be made to multiple molecules that include the compound are discussed, what is specifically contemplated is each and every combination and permutation of the compound and modifications that are possible, unless otherwise specifically indicated to the contrary. Thus, when a class of molecules A, B, and C is disclosed, as well as a class of molecules D, E, and F, and an example of a combination molecule AD is disclosed, this means that each is individually and collectively contemplated, even if each is not individually mentioned, and the combinations AE, AF, BD, BE, BF, CD, CE, and CF are considered to be disclosed. Similarly, any subsets or combinations of these are disclosed. Thus, for example, the subgroups AE, BF, and CE may be considered to be disclosed. This concept applies to all aspects of this application, including but not limited to steps in the methods of making and using the compositions of this disclosure. Thus, where there are various additional steps that can be performed, it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the methods of this disclosure.

[0087] In this specification and the appended claims, reference to parts by weight of a particular component or ingredient in a composition or article indicates the weight relationship, expressed in parts by weight, between that component or ingredient and the other components or ingredients in the composition or article. Thus, in a compound containing 2 parts by weight of component X and 5 parts by weight of component Y, X and Y are present in a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are included in the compound.

[0088] Weight percentages of components are based on the total weight of the formulation or composition in which the component is included, unless specifically stated to the contrary.

[0089] The terms "residue" and "structural unit" as used with respect to components of a polymer are synonymous throughout this specification.

[0090] Unless otherwise stated herein to the contrary, all testing standards are the latest standards in effect at the time of filing this application. Each of the materials disclosed herein is commercially available and / or methods for its manufacture are known to those of skill in the art.

[0091] It is understood that the compositions disclosed herein have specific functions. Disclosed herein are specific structural requirements that perform the disclosed functions, and it is understood that there are various structures that can perform the same functions associated with the disclosed structures, and that these structures typically achieve the same results. Aspects of the Disclosure

[0092] The present disclosure relates to and includes at least the following aspects:

[0093] Aspect 1A. A fiber composition comprising about 10 wt.% to about 99 wt.% of a polymeric resin; and about 0.1 wt.% to about 20 wt.% of a reinforcing filler, wherein the combined weight percentage of all components does not exceed 100 wt.%, all weight percentages being based on the total weight of the composition, the fiber composition being in the form of a fiber, and the fiber exhibiting a tensile modulus of greater than 1950 MPa when tested in accordance with ISO 527.

[0094] Aspect 1B. A fiber composition comprising about 10 wt.% to about 99 wt.% of a polymeric resin; and about 0.1 wt.% to about 20 wt.% of a reinforcing filler, wherein the combined weight percentage of all components does not exceed 100 wt.%, all weight percentages being based on the total weight of the composition, the fiber composition being in the form of a fiber, and the fiber exhibiting a tensile modulus of greater than 1950 MPa when tested in accordance with ISO 527.

[0095] Aspect 1C. A fiber composition consisting essentially of about 10 wt.% to about 99 wt.% polymeric resin; and about 0.1 wt.% to about 20 wt.% reinforcing filler, wherein the combined weight percentage of all components does not exceed 100 wt.%, all weight percentages being based on the total weight of the composition, the fiber composition being in the form of a fiber, and the fiber exhibiting a tensile modulus of greater than 1950 MPa when tested in accordance with ISO 527.

[0096] A fiber composition comprising about 10 wt.% to about 99 wt.% of a polymeric resin comprising a chemically upcycled polybutylene terephthalate (PBT) component derived from post-consumer recycled (PCR) polyester; and about 0.1 wt.% to about 20 wt.% of a reinforcing filler, wherein the combined weight percentage of all components does not exceed 100 wt.%, and all weight percentages are based on the total weight of the composition, the fiber composition is in the form of a fiber, and the fiber exhibits a tensile modulus of greater than 1950 MPa when tested in accordance with ISO 527.

[0097] Embodiment 2. The fiber composition of any one of embodiments 1A-1C, wherein the polymeric resin comprises a semi-crystalline polymer.

[0098] Embodiment 3. The fiber composition of any one of embodiments 1A-1C, wherein the polymeric resin comprises a polyamide or a polyester.

[0099] Embodiment 4. The fiber composition of any one of embodiments 1A-1C, wherein the polymeric resin comprises a chemically upcycled polybutylene terephthalate (PBT) component derived from post-consumer recycled (PCR) polyester.

[0100] Embodiment 5. The fiber composition of embodiment 4, wherein the PCR polyester is recycled from polyethylene terephthalate waste.

[0101] Embodiment 6. The fiber composition of any one of Embodiments 1A-5, wherein the fibers have a diameter of about 1 μm to about 10 mm.

[0102] Embodiment 7. The fiber composition of any one of Embodiments 1A-6, wherein the fiber is a monofilament fiber.

[0103] Embodiment 8. The fiber composition of any one of Embodiments 1A-7, wherein the reinforcing filler has an average particle size distribution of less than 10 μm.

[0104] Embodiment 9. The fibrous composition of any one of Embodiments 1A-8, wherein the reinforcing filler comprises talc, wollastonite, glass fiber, carbon fiber, or a combination thereof.

[0105] Aspect 10. Reinforcing filler having an average particle size distribution D of less than 1.5 μm 50 The fiber composition according to any one of embodiments 1A to 9,

[0106] Embodiment 11. The fibrous composition of any one of Embodiments 1A-9, wherein the reinforcing filler comprises talc.

[0107] Aspect 12. The reinforcing filler has an average particle size distribution D of less than 1.2 μm.50 The fiber composition of any one of embodiments 1A-9, comprising a talc having the following formula:

[0108] Embodiment 13. The fiber composition of any one of embodiments 1A-12, wherein the fiber composition further comprises greater than 0 wt.% to about 2 wt.% of an epoxy impact modifier.

[0109] Embodiment 14. The fiber composition of any one of embodiments 1A to 11, wherein the fiber composition further comprises greater than 0 wt.% to about 5 wt.% of at least one stabilizer, wherein the at least one stabilizer comprises a UV stabilizer, a zinc phosphate stabilizer, or a combination thereof.

[0110] Embodiment 15. A textile component, comprising the fiber composition of any one of embodiments 1A to 14.

[0111] Embodiment 16. A monofilament comprising the fiber composition of any one of embodiments 1A to 14.

[0112] Embodiment 17. A method for forming a plurality of polymer fibers, comprising: forming a molten mixture comprising about 60 wt.% to about 99 wt.% of a polymeric resin and about 0.1 wt.% to about 40 wt.% of a reinforcing filler; extruding the molten mixture through a spinneret to form a plurality of filaments; and allowing the plurality of filaments to solidify to form a plurality of polymer fibers, wherein each of the plurality of polymer fibers exhibits a tensile modulus of greater than 1950 megapascals (MPa) when tested in accordance with ISO 527.

[0113] Embodiment 18. The method of embodiment 17, wherein forming the molten mixture comprises melting the polymeric resin.

[0114] EXAMPLES

[0115] The following examples are presented to provide those skilled in the art with a complete disclosure and description of how the compounds, compositions, articles, devices, and / or methods claimed herein are made and evaluated, and are intended to be purely illustrative and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature), but it is desirable to account for some errors and deviations. Unless otherwise indicated, parts are parts by weight, temperature is in ° C. or is at ambient temperature, and pressure is at or near atmospheric pressure. Percentages referring to compositions are in units of wt.% unless otherwise indicated.

[0116] There are numerous variations and combinations of mixing conditions, such as component concentrations, extruder design, feed rates, screw speeds, temperatures, pressures, and other mixing ranges and conditions that can be used to optimize the purity and yield of the products resulting from the described processes. Optimizing such process conditions will require no more than reasonable and routine experimentation. General Materials and Methods

[0117] The fiber compositions described in the following examples were prepared from the ingredients shown in Table 1. Table 1. Ingredients of the formulation [Table 1]

[0118] The formulations were prepared by extruding the pre-blended ingredients using a twin screw extruder. The compositions were melt mixed and extruded. The extrudate was cooled using a water bath before pelletizing. The ingredients were compounded using a 37mm Toshiba TEM-37BS Twin Screw Extruder co-rotating twin screw extruder with the compounding settings listed in Table 2. Table 2. Compounding conditions [Table 2]

[0119] The extruded composition was then formed into a monofilament fiber having a diameter of 300 μm according to the spinning conditions in Table 3. [Table 3]

[0120] The monofilament fibers formed were evaluated for their tensile and modulus performance. The tensile performance of each fiber was measured according to ISO 527 at a test speed of 50 mm / min, from which the property E t , σ b , and ε b I got E t is the elastic modulus expressed in MPa; σ b is the breaking stress in MPa, and ε b is the breaking strain or elongation at break expressed in %. Melt volume rate (MVR) was determined according to ASTM D1238 using granules dried at 90° C. for 4 hours.

[0121] Table 4 shows the comparative samples (C1, C2) and the samples of the invention (EX-1, EX-2) that were prepared. [Table 4]

[0122] C-1 is a control sample with virgin PBT and C-2 is a control sample with rPBT. EX-1 through EX-2 are formulations of the invention using rPBT.

[0123] Compared to C1 (fibers spun from virgin PBT), fibers spun from rPBT compounds show lower modulus and stress. The incorporation of fine talc into rPBT compounds (EX-1 and EX-2) significantly improved modulus and stress. Also, the improvement in modulus and stress increased with increasing talc loading. Reinforced rPBT fibers also showed better performance than virgin PBT fibers.

[0124] The above is intended to be illustrative, not limiting. For example, the above examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments may be readily used, for example, by one of ordinary skill in the art upon review of the above. The Abstract is provided to enable the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. Nonetheless, it should be construed that no unclaimed disclosed feature is intended to be essential to any claim. Rather, the subject matter of the invention may lie in less than all features of a particular disclosed embodiment. Thus, it is contemplated that the appended claims are incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and that such embodiments can be combined with each other in various combinations or permutations. The scope of the present disclosure should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0125] It will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. Other embodiments of the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the present disclosure being indicated by the appended claims.

[0126] The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that have insubstantial differences from the literal language of the claims.

Claims

1. 1. A fiber composition comprising: 40 wt.% to 99 wt.% of a polymeric resin comprising a chemically upcycled polybutylene terephthalate (PBT) component derived from post-consumer recycled (PCR) polyester; 0.1 wt. % to 20 wt. % of a reinforcing filler; the total weight percentage of all components does not exceed 100 wt. %, and all weight percentages are based on the total weight of said composition; The fiber composition is in the form of a fiber, A fiber composition, wherein the fiber exhibits a tensile modulus of greater than 1950 MPa when tested in accordance with ISO 527.

2. 2. The fiber composition of claim 1, wherein the PCR polyester is recycled from polyethylene terephthalate waste.

3. The fiber composition according to any one of claims 1 to 2, wherein the fibers have a diameter of from 1 μm to 10 mm.

4. The fiber composition according to any one of claims 1 to 3, wherein the fiber is a monofilament fiber.

5. The reinforcing filler has an average particle size distribution D of less than 10 μm ９５ The fiber composition according to any one of claims 1 to 4, having the following structure:

6. The fibrous composition of any one of claims 1 to 5, wherein the reinforcing filler comprises talc, wollastonite, glass fiber, carbon fiber, or combinations thereof.

7. The reinforcing filler has an average particle size distribution D of less than 1.5 μm ５０ The fiber composition according to any one of claims 1 to 6, having the following structure:

8. A fiber composition according to any one of claims 1 to 7, wherein the reinforcing filler comprises talc.

9. 9. The fiber composition of any one of claims 1 to 8, wherein the fiber composition further comprises from greater than 0 wt. % to 2 wt. % of an epoxy impact modifier.

10. 10. The fiber composition of any one of claims 1 to 9, wherein the fiber composition further comprises from greater than 0 wt.% to 5 wt.% of at least one stabilizer, the at least one stabilizer comprising a UV stabilizer, a zinc phosphate stabilizer, or a combination thereof.

11. A monofilament comprising the fiber composition according to any one of claims 1 to 10.

12. 1. A method of forming a plurality of polymer fibers, comprising: a. forming a molten mixture comprising 60 wt. % to 99 wt. % of a polymeric resin, the polymeric resin comprising a chemically upcycled polybutylene terephthalate (PBT) component derived from post-consumer recycled (PCR) polyester, and 0.1 wt. % to 40 wt. % of a reinforcing filler; b. extruding the molten mixture through a spinneret to form a plurality of filaments; c. allowing the plurality of filaments to solidify to form the plurality of polymer fibers; wherein each of the plurality of polymeric fibers exhibits a tensile modulus greater than 1950 megapascals (MPa) when tested in accordance with ISO 527.

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