Thermoplastic elastomer multifilament yarn

Abstract

This invention discloses a thermoplastic elastomer multifilament yarn and a method for producing a thermoplastic elastomer multifilament yarn. The multifilament yarn includes a first filament that is at least partially adhered to a second filament. The first and second filaments are each formed from a thermoplastic elastomer composition containing 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. 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 more, as measured according to ASTM D2653-07(2018) at a temperature of about 23°C.

Description

[Technical Field]

[0001] Cross-reference of related applications This application claims the benefit of filing U.S. Provisional Patent Application No. 63 / 498,862, filed on 28 April 2023, which is incorporated herein by reference in its entirety. [Background technology]

[0002] Non-stretchable yarns, such as polyester and nylon, are commonly used to manufacture articles such as cloth and furniture. The filaments used to produce such yarns can be spun with minimal filament breakage, and corresponding breakage can also be minimized during fabric processing. Another class of materials, namely thermoplastic elastomers, have recently been used for a variety of applications due to their ability to function as thermoplastics, particularly their ability to remodel upon heating, while also exhibiting specific properties typical of elastomers. As a result, these materials can also be used as elastomeric stretchable yarns for forming various articles. However, these yarns may have a higher-than-desirable tendency to break during spinning and / or further processing. In addition, when using multifilament yarns made from such thermoplastic elastomers, individual filaments may separate from the yarn bundle during unwinding and / or further processing, thereby compromising the integrity of the yarn and the resulting article. [Overview of the project] [Problems that the invention aims to solve]

[0003] Therefore, in order to provide improved thermoplastic elastomer multifilaments and the resulting yarns and articles, there remains a need to overcome certain problems associated with the use of thermoplastic elastomers. [Means for solving the problem]

[0004] A multifilament yarn is disclosed according to one embodiment of the present disclosure. The multifilament yarn comprises a first filament at least partially bonded to a second filament. The first and second filaments are each formed from 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. 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 more as measured according to ASTM D2653-07(2018) at a temperature of about 23°C.

[0005] A method for producing the aforementioned multifilament yarn is disclosed according to another embodiment of the present disclosure. This method includes extruding a molten material containing a thermoplastic elastomer composition containing a thermoplastic elastomer through a spinneret; drawing out a first filament and a second filament from the spinneret; and collecting the first filament and the second filament on a winding roller.

[0006] Other features and aspects of this disclosure are described in more detail below.

[0007] The full and authorized disclosures of this disclosure, including references to the attached figures, are described more specifically in the remainder of this specification. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic process diagram of an apparatus useful for manufacturing filaments according to one embodiment of the present disclosure. [Figure 2A] This is a cross-sectional view of a filament having a two-lobe cross-section according to one embodiment of the present disclosure. [Figure 2B] This is a cross-sectional view of a filament having a two-lobe cross-section according to one embodiment of the present disclosure. [Figure 2C] This is a cross-sectional view of a two-filament multifilament according to another embodiment of the present disclosure. [Figure 3A]Cross-sectional view of a monofilament having a three-lobe cross-section according to another embodiment of the present disclosure. [Figure 3B] Cross-sectional view of a monofilament having a three-lobe cross-section according to another embodiment of the present disclosure. [Figure 3C] Cross-sectional view of a monofilament having a three-lobe cross-section according to another embodiment of the present disclosure. [Figure 4A] Cross-sectional view of a monofilament having a four-lobe cross-section according to another embodiment of the present disclosure. [Figure 4B] Cross-sectional view of a monofilament having a four-lobe cross-section according to another embodiment of the present disclosure. [Figure 4C] Cross-sectional view of a monofilament having a four-lobe cross-section according to another embodiment of the present disclosure. [Figure 5] Cross-sectional view of a three-filament multifilament according to another embodiment of the present disclosure. [Figure 6] Cross-sectional view of a four-filament multifilament according to another embodiment of the present disclosure. [Figure 7] Shows a knit structure according to an embodiment of the present disclosure. [Figure 8] Provides an optical micrograph of the multifilament yarn of Example 1.

MODE FOR CARRYING OUT THE INVENTION

[0009] The repeated use of reference characters in this specification and the drawings is intended to represent the same or similar features or elements of the present invention. [[ID=३७]]

[0010] It should be understood by those skilled in the art that this discussion is only an explanation of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0011] Generally speaking, this disclosure relates to thermoplastic elastomer multifilament yarns. The inventors have found that by utilizing thermoplastic elastomers as described herein to form multifilament yarns having the configurations described herein, the filaments and yarns can exhibit desired properties for a variety of applications, particularly textile applications. In particular, articles produced from multifilament yarns may be lighter, dry faster, and / or be more breathable than those made from other materials. In addition, since thermoplastic elastomers can be reformed by heating, like thermoplastic plastics, yarns formed from thermoplastic elastomers and articles produced from them may contribute to a recyclable and circular ecosystem. For example, these materials may be reused and reformed, and therefore, unlike other types of materials typically used, may not necessarily have to be disposed of.

[0012] In addition, the properties of thermoplastic elastomers and the resulting filaments and yarns enable the use of these materials to overcome certain previous problems. For example, yarns with elongation exceeding 300% can be spun at relatively high speeds to form the resulting articles while minimizing filament and yarn breakage. Furthermore, yarns can also result in fewer defects during knitting applications (e.g., drop stitches, holes, poor selvage, broken filaments, yarn breakage, inconsistent yarn denier in the fabric, etc.).

[0013] In particular, yarns such as those disclosed herein may provide elasticity or resilience, and without being intended to be limited by theory, such elasticity / resilience may contribute to the ability of the yarn to be used while minimizing yarn breakage. In this regard, the elongation at break of the yarn may be about 300% or more, e.g., about 325% or more, e.g., about 350% or more, e.g., about 375% or more, e.g., about 400% or more, e.g., about 450% or more, e.g., about 500% or more, e.g., about 600% or more, e.g., about 800% or more, e.g., about 1000% or more, etc. The elongation at break may be approximately 2000% or less, e.g., approximately 1800% or less, e.g., approximately 1600% or less, e.g., approximately 1400% or less, e.g., approximately 1200% or less, e.g., approximately 1000% or less, e.g., approximately 900% or less, e.g., approximately 800% or less, e.g., approximately 700% or less, e.g., approximately 600% or less, e.g., approximately 550% or less, e.g., approximately 500% or less, e.g., approximately 475% or less, e.g., approximately 450% or less, e.g., approximately 425% or less, e.g., approximately 400% or less, e.g., approximately 375% or less, etc. Furthermore, since the yarn can exhibit such relatively high elongation at break, it can also be generally called an elastic yarn. The elongation at break can be measured according to ASTM D2653-07(2018) at a temperature of approximately 23°C.

[0014] In addition to elongation at break, the yarn may also exhibit a desired strength, as indicated by its tenacity. For example, the tenacity may be about 0.7 grams / denier (g / d) or more, e.g., about 0.75 g / d or more, e.g., about 0.8 g / d or more, e.g., about 0.85 g / d or more, e.g., about 0.9 g / d or more, e.g., about 0.95 g / d or more, e.g., about 1 g / d or more, e.g., about 1.05 g / d or more, e.g., about 1.1 g / d or more, e.g., about 1.15 g / d or more, e.g., about 1.2 g / d or more, e.g., about 1.4 g / d or more, e.g., about 1.6 g / d or more, e.g., about 1.8 g / d or more, e.g., about 2 g / d or more, e.g., about 2.5 g / d or more, e.g., about 3 g / d or more, e.g., about 4 g / d or more, e.g., about 5 g / d or more, and so on. Tenacity may be approximately 10 g / d or less, e.g., approximately 8 g / d or less, e.g., approximately 6 g / d or less, e.g., approximately 5 g / d or less, e.g., approximately 4 g / d or less, e.g., approximately 3.5 g / d or less, e.g., approximately 3 g / d or less, e.g., approximately 2.5 g / d or less, e.g., approximately 2 g / d or less, e.g., approximately 1.8 g / d or less, e.g., approximately 1.6 g / d or less, e.g., approximately 1.4 g / d or less, e.g., approximately 1.2 g / d or less, e.g., approximately 1.15 g / d or less, e.g., approximately 1.1 g / d or less, e.g., approximately 1.05 g / d or less, e.g., approximately 1 g / d or less. Tenacity may be measured at a temperature of approximately 23°C according to ASTM D2653-07 (2017).

[0015] In addition, even with relatively high elongation at the breaking point, the yarn may nevertheless exhibit relatively low shrinkage. For example, shrinkage may be approximately 50% or less, approximately 40% or less, approximately 35% or less, approximately 30% or less, approximately 25% or less, approximately 20% or less, approximately 15% or less, approximately 10% or less, approximately 9% or less, approximately 8.5% or less, approximately 8% or less, approximately 7.5% or less, approximately 7% or less, approximately 6.5% or less, approximately 6% or less, approximately 5.5% or less, approximately 5% or less, approximately 4.5% or less, approximately 4% or less, approximately 3.5% or less, approximately 3% or less, approximately 2.5% or less, etc. Shrinkage may be approximately 0% or more, e.g., approximately 0.1% or more, e.g., approximately 0.3% or more, e.g., approximately 0.5% or more, e.g., approximately 1% or more, e.g., approximately 1.5% or more, e.g., approximately 2% or more, e.g., approximately 2.5% or more, e.g., approximately 3% or more, e.g., approximately 3.5% or more, e.g., approximately 4% or more, e.g., approximately 4.5% or more, e.g., approximately 5% or more, e.g., approximately 5.5% or more, e.g., approximately 6% or more, e.g., approximately 6.5% or more, e.g., approximately 7% or more, e.g., approximately 7.5% or more, e.g., approximately 10% or more, e.g., approximately 15% or more, e.g., approximately 20% or more, e.g., approximately 25% or more, etc. Shrinkage may be measured according to ASTM D2259-02 (2016) (Section 6.6.1, Step 13, Dry heat exposure at a temperature of approximately 120°C).

[0016] In connection with this, the yarn may have recoverable elasticity of at least about 75%, for example at least about 80%, for example at least about 85%, for example at least about 90%, for example at least about 93%, for example at least about 95%, for example at least about 100%, for example at least about 125%, for example at least about 150%, for example at least about 175%, for example at least about 200%, for example at least about 225%, for example at least about 250%, etc. The recoverable elasticity may be about 500% or less, for example at least about 450%, for example at least about 400%, for example at least about 350%, for example at least about 300%, for example at least about 250%, for example at least about 200%, for example at least about 150%, for example at least about 140%, for example at least about 130%, for example at least about 120%, for example at least about 110%, for example at least about 105%, for example at least about 100%, etc. Therefore, the yarn can be stretched to 1.5 times (150%) its original length and quickly and substantially recover to its original length when released. The recoverable stretch can be measured according to ASTM D6720-07 (2018).

[0017] Thermoplastic elastomers used in the manufacture of filaments and threads may also exhibit certain mechanical strengths in order to obtain such beneficial properties as relatively high elongation at break and / or relatively low shrinkage. In particular, thermoplastic elastomers may be less resistant to deformation in bending compared to other types of materials, and as a result, thermoplastic elastomers may exhibit relatively low flexural modulus. For example, the flexural modulus could be approximately 300 MPa or less, approximately 260 MPa or less, approximately 220 MPa or less, approximately 200 MPa or less, approximately 190 MPa or less, approximately 180 MPa or less, approximately 170 MPa or less, approximately 160 MPa or less, approximately 150 MPa or less, approximately 140 MPa or less, approximately 130 MPa or less, approximately 120 MPa or less, approximately 110 MPa or less, approximately 100 MPa or less, approximately 90 MPa or less, approximately 80 MPa or less, approximately 70 MPa or less, approximately 60 MPa or less, approximately 50 MPa or less, approximately 40 MPa or less, approximately 30 MPa or less, approximately 20 MPa or less, etc. The flexural modulus can be approximately 10 MPa or higher, for example approximately 15 MPa or higher, for example approximately 20 MPa or higher, for example approximately 25 MPa or higher, for example approximately 30 MPa or higher, for example approximately 35 MPa or higher, for example approximately 40 MPa or higher, for example approximately 45 MPa or higher, for example approximately 50 MPa or higher, for example approximately 60 MPa or higher, for example approximately 70 MPa or higher, for example approximately 80 MPa or higher, for example approximately 90 MPa or higher, for example approximately 100 MPa or higher, for example approximately 110 MPa or higher, for example approximately 120 MPa or higher, for example approximately 130 MPa or higher, for example approximately 140 MPa or higher, for example approximately 150 MPa or higher, for example approximately 180 MPa or higher, for example approximately 200 MPa or higher, etc. The flexural modulus can be measured at a temperature of approximately 23°C according to ISO 178:2019.

[0018] In connection with this, thermoplastic elastomers may have a specific Shore D hardness, which can provide an indicator of the indentation resistance of the thermoplastic elastomer. In connection with this, the Shore D hardness may be about 15 or higher, e.g., about 20 or higher, e.g., about 25 or higher, e.g., about 30 or higher, e.g., about 35 or higher, e.g., about 40 or higher, e.g., about 45 or higher, e.g., about 50 or higher, e.g., about 60 or lower, e.g., about 55 or lower, e.g., about 50 or lower, e.g., about 45 or lower, e.g., about 40 or lower, e.g., about 35 or lower, e.g., about 30 or lower, e.g., about 30 or lower. Such hardness may enable the thermoplastic elastomer to provide the compliance necessary to function effectively for use in filaments / yarns and the resulting articles. The Shore D hardness may be measured according to ISO 868-2003 (15 seconds).

[0019] In addition, thermoplastic elastomers may possess other beneficial mechanical properties. For example, the tensile stress at fracture may be approximately 45 MPa or less, e.g., approximately 40 MPa or less, e.g., approximately 35 MPa or less, e.g., approximately 30 MPa or less, e.g., approximately 30 MPa or less, e.g., approximately 25 MPa or less. The tensile stress at fracture may be approximately 5 MPa or more, e.g., approximately 10 MPa or more, e.g., approximately 15 MPa or more, e.g., approximately 20 MPa or more, e.g., approximately 25 MPa or more, e.g., approximately 30 MPa or more, e.g., approximately 35 MPa or more. The tensile stress at fracture can be measured at a temperature of approximately 23°C according to ISO 527-1 / -2 (2012).

[0020] Furthermore, thermoplastic elastomers may have relatively high nominal fracture strain. For example, the nominal fracture strain may be approximately 200% or more, for example approximately 250% or more, for example approximately 300% or more, for example approximately 350% or more, for example approximately 400% or more, for example approximately 450% or more, for example approximately 500% or more, for example approximately 550% or more, for example approximately 600% or more, for example approximately 650% or more, for example approximately 700% or more, for example approximately 750% or more, for example approximately 800% or more, for example approximately 850% or more, and so on. The nominal fracture strain may be approximately 2000% or less, e.g., approximately 1800% or less, e.g., approximately 1600% or less, e.g., approximately 1400% or less, e.g., approximately 1200% or less, e.g., approximately 1100% or less, e.g., approximately 1000% or less, e.g., approximately 950% or less, e.g., approximately 900% or less, e.g., approximately 850% or less, e.g., approximately 800% or less, e.g., approximately 700% or less, e.g., approximately 600% or less, e.g., approximately 500% or less, etc. The nominal fracture strain may be measured at a temperature of approximately 23°C according to ISO 527-1 / -2(2012).

[0021] Various embodiments of this disclosure will now be described in more detail.

[0022] I. Thermoplastic Elastomer Compositions Generally, yarns such as those disclosed herein are formed from one or more thermoplastic elastomers. In this regard, one or more thermoplastic elastomers may be given 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 certain embodiments, one or more thermoplastic elastomers may constitute a composition as a whole (e.g., without the incorporation of one or more additives).

[0023] A. Thermoplastic elastomers As shown above, a thermoplastic elastomer composition comprises one or more thermoplastic elastomers. A thermoplastic elastomer may be defined according to ISO 18064:2003(E). For example, a thermoplastic elastomer may 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 a particular 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.

[0024] In one embodiment, the thermoplastic elastomer may be a thermoplastic polyolefin elastomer. Generally, thermoplastic polyolefin elastomers include polypropylene or polyethylene blended with a thermoplastic olefin polymer, such as a thermosetting elastomer. For example, a typical thermoplastic polyolefin elastomer may include a melt blend or reactor blend of polyolefin and an olefin copolymer elastomer. The polyolefin may be polyethylene or polypropylene, preferably polypropylene. The olefin copolymer elastomer may be an ethylene copolymer. For example, an ethylene copolymer may include ethylene and another olefin monomer, particularly an alpha-olefin monomer. For example, an ethylene copolymer may include ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-hexene copolymer, ethylene-octene copolymer, and / or ethylene-butadiene. In particular, the copolymer may be an ethylene-propylene copolymer, particularly an ethylene-propylene-diene copolymer.

[0025] In one embodiment, the thermoplastic elastomer may be a thermoplastic styrene-based elastomer. Generally, thermoplastic styrene-based elastomers include block copolymers of polystyrene and a rubbery polymer material. The rubbery polymer material may include, but is not limited to, polybutadiene, a mixture of hydrogenated polybutadiene and 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.

[0026] In one embodiment, the thermoplastic elastomer may be a thermoplastic polyurethane. Generally, thermoplastic polyurethanes have the general formula: [ka] (In the formula, "X" represents a hard segment containing diisocyanate and short-chain glycol. "Z" represents a soft segment containing diisocyanates and long-chain polyols. ("Y" represents a residue of the urethane bond diisocyanate compound that connects the X and Z segments.) As shown, it comprises a linear segmented block copolymer consisting of a hard segment containing diisocyanate and a short-chain glycol, and a soft segment containing diisocyanate and a long-chain polyol. Long-chain polyols may include polyether-type or polyester-type polyols such as poly(alkylene oxide) glycols.

[0027] In one embodiment, the thermoplastic elastomer may be a thermoplastic polyamide block copolymer. Generally, thermoplastic polyamide block copolymers have a general formula: [ka] (In the formula, "PA" stands for linear saturated aliphatic polyamide sequence. "PE" represents a polyoxyalkylene sequence formed from linear or branched aliphatic polyoxyalkylene glycols or long-chain polyols having either ether linkages, ester linkages, or both, and mixtures thereof, or copolyethers and copolyesters derived therefrom. n is an integer greater than 1. It includes linear and regular chains of polyamide segments and flexible polyether or polyester segments or soft segments having ether and ester bonds, as represented by [the formula shown]. The softness of copolyetheramide block copolymers or copolyesteramide block copolymers generally decreases as the relative amount of polyamide units increases.

[0028] 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 particular embodiment, the thermoplastic polyester elastomer may be a thermoplastic copolyether ester elastomer.

[0029] As shown above, thermoplastic polyester elastomers can be copolyester ester elastomers. Generally, copolyester ester 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(cyclohexanedicarboxylic acid cyclohexanemethanol), etc. Examples of soft polyester segments include, but are not limited to, polybutylene adipate, polytetramethyl adipate, and polycaprolactone, etc. Examples of aliphatic polyesters include, but are not limited to, polybutylene adipate, polytetramethyl adipate, and polycaprolactone.

[0030] Copolyester elastomers may contain one or more blocks of ester units of high-melting-point polyesters and one or more blocks of ester units of low-melting-point polyesters, which are bonded together by ester groups or urethane groups. Copolyester elastomers containing urethane groups may be prepared by reacting different polyesters in the molten phase, and then reacting the resulting copolyester ester with a low molecular weight polyisocyanate. The polyisocyanate may be a diisocyanate or a triisocyanate. In particular, the polyisocyanate may be a diisocyanate such as p-toluene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, hexamethylene diisocyanate, and / or isophorone diisocyanate.

[0031] As shown above, thermoplastic polyester elastomers can be copolyether ester elastomers. Generally, copolyether ester elastomers may have multiple repeating long-chain and short-chain ester units linked by ester bonds. The long-chain ester unit is given by formula (A): [ka] It can be expressed as, The short-chain ester unit is given by formula (B): [ka] It can be expressed as, During the ceremony G is a divalent group remaining after the removal of terminal hydroxyl groups from a long-chain polymer glycol having a number average molecular weight of about 400 to about 6000, preferably about 400 to about 3000, and more preferably about 600 to about 3000; R is a divalent group that remains after the removal of the carboxyl group from a dicarboxylic acid having a number average molecular weight of less than approximately 300; D is the divalent group that remains after the removal of the hydroxyl group from a diol having a number-average molecular weight of less than approximately 250.

[0032] As used herein, the term “long-chain ester unit” refers to the reaction product of a long-chain glycol and a dicarboxylic acid. Long-chain glycols are polymer glycols having terminal (or as close to the terminal as possible) hydroxyl groups. Particularly preferred long-chain glycols include poly(alkylene oxide) glycols having terminal (or as close to the terminal as possible) hydroxyl groups and number-average molecular weights such as about 400 to about 6000, for example, about 400 to about 3000, for example, about 600 to about 3000, for example, about 1000 to about 3000, for example, about 1000 to about 2000. In addition, long-chain glycols may have melting points such as less than about 65°C, for example, less than about 60°C, for example, less than about 55°C, for example, less than about 50°C. Long-chain glycols are generally glycol esters of poly(alkylene oxide) glycols or poly(alkylene oxide) dicarboxylic acids. Preferred poly(alkylene oxide) glycols include poly(tetramethylene oxide) glycol, poly(trimethylene oxide) glycol, poly(propylene oxide) glycol (e.g., 1,2- or 1,3-propylene oxide), poly(ethylene oxide) glycol, poly(hexamethylene oxide) glycol, poly(heptamethylene oxide) glycol, poly(octamethylene oxide) glycol, poly(nonamethylene oxide) glycol, and poly(1,2-butylene oxide) glycol, copolymer glycols of these alkylene oxides, and block copolymers such as ethylene oxide-capped poly(propylene oxide) glycol. It should also be understood that mixtures of two or more of these glycols may be used. Furthermore, in some cases, any substituents that do not hinder the polymerization of the compound with the glycol or dicarboxylic acid may be present. The hydroxyl functional groups of the long-chain glycols that react to form copolyesters may be terminal groups whenever possible. The terminal hydroxyl group can be located on an ethylene oxide terminal group on an end-capping glycol unit (e.g., poly(propylene oxide glycol)) that is different from the chain. The long-chain ester unit of formula (A) is also sometimes referred to as the “soft segment” of the copolyether ester elastomer.

[0033] 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, e.g., less than about 525, e.g., less than about 500, e.g., less than about 475, e.g., less than 450. They can generally be produced by reacting a low molecular weight diol or mixture of diols (molecular weight less than about 250, e.g., less than about 225, e.g., less than about 200, e.g., less than about 175, e.g., less than 150) with a dicarboxylic acid to form the ester unit represented by formula (B) above. The short-chain ester unit of formula (B) is also sometimes referred to as the “hard segment” of a copolyether ester polymer.

[0034] Low molecular weight diols that react to form short-chain ester units to prepare copolyesters include acyclic, alicyclic, and aromatic dihydroxy compounds. These compounds include diols having about 2 to about 15 carbon atoms, for example, about 2 to about 8 carbon atoms, for example, about 2 to about 6 carbon atoms, such as ethylene, propylene, isobutylene, tetramethylene, 1,4-pentamethylene, 2,2-dimethyltrimethylene, hexamethylene and decamethylene glycol, dihydroxycyclohexane, cyclohexanedimethanol, resorcinol, hydroquinone, 1,5-dihydroxynaphthalene, etc. In particular, the diol may be an aliphatic diol, for example, 1,4-butanediol, ethylene glycol, 1,3-propanediol, cyclohexanedimethanol, and / or hexamethylene glycol. For example, the diol may be ethylene glycol, 1,4-butanediol, 1,3-propanediol, or a combination thereof. In particular, 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, cyclohexanedimethanol, and / or hexamethylene glycol. Among the bisphenols that can be used are bis(p-hydroxy)diphenyl, bis(p-hydroxyphenyl)methane, and bis(p-hydroxyphenyl)propane. Equivalent ester-forming derivatives of the diol are also useful (for example, ethylene oxide or ethylene carbonate can be used instead of ethylene glycol, or resorcinol diacetate can be used instead of resorcinol).

[0035] As used herein, the term “diol” includes equivalent esterifying derivatives such as those mentioned. However, the molecular weight requirements refer to the corresponding diols and not to their derivatives.

[0036] Examples of dicarboxylic acids that can be reacted with the aforementioned long-chain glycols and low-molecular-weight diols to produce copolyether esters include aliphatic, alicyclic, or aromatic dicarboxylic acids with low molecular weights (e.g., having molecular weights of less than about 300, e.g., less than about 275, e.g., less than about 250, e.g., less than about 225). The term “dicarboxylic acid” as used herein includes functional equivalents of dicarboxylic acids having two carboxyl functional groups that function substantially like a dicarboxylic acid in the reaction with glycols and diols when forming thermoplastic copolyether ester elastomers. These equivalents include esters and ester-forming derivatives such as acid halides and acid anhydrides. The molecular weight requirement is related to the acid and not to its equivalent ester or ester-forming derivative.

[0037] Therefore, dicarboxylic acids having a molecular weight greater than 300 or esters of functional equivalents of dicarboxylic acids having a molecular weight greater than 300 are also suitable, provided that the corresponding acid has a molecular weight of less than approximately 300 or the aforementioned molecular weight. The dicarboxylic acid may contain any substituents or combinations that do not substantially hinder the formation of the thermoplastic copolyether ester elastomer and the use of the thermoplastic copolyether ester elastomer in the composition.

[0038] As used herein, the term “aliphatic dicarboxylic acid” refers to a carboxylic acid having two carboxyl groups bonded to a saturated carbon atom, each bonded to a saturated carbon atom. An acid is alicyclic if the carbon atom to which the carboxyl groups are bonded is saturated and located within a ring. Aliphatic or alicyclic acids with conjugated unsaturation are often unsuitable for homopolymerization. However, some unsaturated acids, such as maleic acid, may be used.

[0039] As used herein, the term “aromatic dicarboxylic acid” refers to a dicarboxylic acid having two carboxyl groups bonded to carbon atoms in a carbocyclic aromatic ring structure. It is not necessary for both functional carboxyl groups to be bonded to the same aromatic ring; if two or more rings are present, they can be joined by aliphatic or aromatic divalent groups or divalent groups such as -O- or -SO2-.

[0040] Representative aliphatic and alicyclic acids that can 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-ethylsvelic acid; cyclopentanedicarboxylic acid, decahydro-1,5-naphthylenedicarboxylic acid; 4,4'-bicyclohexyldicarboxylic acid; decahydro-2,6-naphthylenedicarboxylic acid; 4,4'-methylenebis(cyclohexyl)carboxylic acid; 3,4-franzicarboxylic acid; and mixtures thereof. In one embodiment, preferred acids may include cyclohexanedicarboxylic acid and / or adipic acid.

[0041] Representative aromatic dicarboxylic acids that can be used include phthalic acid, terephthalic acid and isophthalic acid; bibenzoic acid; substituted dicarboxy 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'-sulfonyldibenzoic acid, as well as halo, alkoxy, and aryl derivatives, etc., of which C1-C 12 Examples include, but are not limited to, alkyl and ring-substituted derivatives, as well as mixtures thereof. Hydroxy acids such as p-(beta-hydroxyethoxy)benzoic acid may also be used, provided that aromatic dicarboxylic acids are also used.

[0042] In one embodiment, aromatic dicarboxylic acids are preferred for preparing thermoplastic copolyether ester elastomers. Among aromatic dicarboxylic acids, those having 8 to 16 carbon atoms, for example 8 to 12 carbon atoms, for example 8 to 10 carbon atoms, may be preferred. In particular, aromatic dicarboxylic acids may include terephthalic acid, phthalic acid, and / or isophthalic acid. In particular, aromatic dicarboxylic acids may include terephthalic acid alone or a mixture of terephthalic acid and / or isophthalic acid.

[0043] When a mixture of two or more dicarboxylic acids is used to prepare a copolyether ester, isophthalic acid may be a preferred second dicarboxylic acid in one embodiment. For example, isophthalic acid may be provided in a mixture with terephthalic acid. In this regard, the amount of copolymerized isophthalate residues in the copolyether ester may be less than 35 mol%, for example less than 30 mol%, for example less than 25 mol%, etc. Similarly, the copolymerized isophthalate residues in the copolyether ester may be less than 35 wt%, for example less than 30 wt%, for example less than 25 wt%, etc., based on the total weight of copolymerized dicarboxylic acid residues -(-C(O)RC(O)-)- in the copolyether ester. The remainder of the phenylene divalent groups may be derived from terephthalic acid based on the total number of moles of copolymerized dicarboxylic acid residues -(-C(O)RC(O)-)- in the copolyether ester.

[0044] Furthermore, in one embodiment, at least about 70 mol% of the group represented by R in formulas (A) and (B) above may be a 1,4-phenylene group, and at least about 70 mol% of the group represented by D in formula (B) above may be a 1,4-butylene group, and the sum of the percentages of the R group that is not a 1,4-butylene group and the D group that is not a 1,4-butylene group may not exceed 30 mol%.

[0045] For example, a copolyether ester may have a hard segment consisting of polybutylene terephthalate and a soft segment consisting of reaction products of polyether glycol and aromatic diacitors in amounts of about 5% to about 80% by weight, e.g., about 5% to about 75% by weight, e.g., about 10% to about 70% by weight, e.g., about 10% to about 60% by weight, e.g., about 20% to about 60% by weight. The polyether block may be derived from polytetramethylene glycol. Complementarily, the proportion of the hard segment may be about 20% to about 95% by weight, e.g., about 20% to about 90% by weight, e.g., about 30% to about 90% by weight, e.g., about 40% to about 90% by weight, e.g., about 40% to about 80% by weight.

[0046] Preferred thermoplastic copolyether ester elastomers, though not limited to them, include: (A) (1) poly(tetramethylene oxide) 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(trimethylene oxide) 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) prepared from monomers comprising (1) ethylene oxide-capped poly(propylene oxide) 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.

[0047] Preferably, the thermoplastic copolyether ester elastomer can be prepared from an ester or mixture of esters of terephthalic acid or isophthalic acid, and 1,4-butanediol and poly(tetramethylene ether) glycol, poly(trimethylene ether) glycol, or polypropylene oxide glycol capped with ethylene oxide, or from an ester of terephthalic acid (e.g., dimethyl terephthalate), 1,4-butanediol, and poly(ethylene oxide) glycol. More preferably, the thermoplastic copolyether ester elastomer can be prepared from an ester of terephthalic acid (e.g., dimethyl terephthalate), 1,4-butanediol, and poly(tetramethylene ether) glycol.

[0048] For example, in one particular embodiment, the thermoplastic copolyether ester elastomer is of the following formula:-[4GT] x -[BT] y -(wherein the formula, 4G is a butylene glycol residue such as 1,4-butanediol, B is a poly(tetramethylene ether glycol) residue, T is terephthalate, x is approximately 0.60 to 0.99, and y is approximately 0.01 to 0.40).

[0049] In one embodiment, the thermoplastic copolyether ester elastomer can be a block copolymer of polybutylene terephthalate and a polyether segment, with the following structure: [ka] (In the formula, a and b are integers and can range from 2 to 10,000.) It can have the following properties. The ratio between hard segments and soft segments in the block copolymer described above can be changed to alter the properties of the elastomer.

[0050] Generally, thermoplastic copolyether ester elastomers preferably contain copolymer residues (hard segments) of long-chain ester units corresponding to formula (A) above, such as about 1% by weight or more, for example, about 5% by weight or more, for example, about 10% by weight or more, for example, about 20% by weight or more, for example, about 25% by weight or more, for example, about 30% by weight or more, for example, about 35% by weight or more, for example, about 40% by weight or more, for example, about 45% by weight or more, for example, about 50% by weight or more, for example, about 55% by weight or more. Thermoplastic copolyether ester elastomers preferably contain copolymer residues (hard segments) of long-chain ester units corresponding to formula (A) above, such as about 85% by weight or less, for example, about 80% by weight or less, for example, about 75% by weight or less, for example, about 70% by weight or less, for example, about 65% by weight or less, for example, about 60% by weight or less.

[0051] Generally, thermoplastic copolyether ester elastomers preferably contain copolymer residues (soft segments) of short-chain ester units corresponding to the above formula (B) in amounts of about 10% by weight or more, for example, about 20% by weight or more, for example, about 25% by weight or more, for example, about 30% by weight or more, for example, about 35% by weight or more, for example, about 40% by weight or more, for example, about 45% by weight or more, for example, about 50% by weight or more. Thermoplastic copolyether ester elastomers preferably contain copolymer residues (soft segments) of short-chain ester units corresponding to the above formula (B) in amounts of about 99% by weight or less, for example, about 95% by weight or less, for example, about 90% by weight or less, for example, about 85% by weight or less, for example, about 80% by weight or less, for example, about 75% by weight or less, for example, about 70% by weight or less, for example, about 65% by weight or less, for example, about 60% by weight or less, for example, about 55% by weight or less.

[0052] In one embodiment, the thermoplastic copolyether ester elastomer may contain only copolymerized residues of long-chain ester units corresponding to formula (A) and short-chain ester units corresponding to formula (B). In this regard, the weight percentages of the copolymerized units of formula (A) and formula (B) in the copolyether ester may be complementary. That is, the sum of the weight percentages of the copolymerized units of formula (A) and formula (B) may be 100% by weight. Similarly, the molar percentages of the R groups in the copolymerized units of formula (A) and formula (B) in the copolyether ester copolymer may be complementary. That is, the sum of the molar percentages of the R groups in the copolymerized units of formula (A) and formula (B) may be 100 mol%.

[0053] 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 contain a mixture of thermoplastic elastomers. For example, two or more thermoplastic elastomers, such as two or three thermoplastic elastomers, can be used in the composition.

[0054] Specifically, with respect to thermoplastic polyester elastomers, particularly mixtures of thermoplastic copolyether ester elastomers, each elastomer used does not need to fall within the values ​​described above for each elastomer individually. However, in this regard, a mixture of two or more thermoplastic copolyether ester elastomers may conform to the values ​​described herein for copolyether esters on a weighted average basis. For example, in a mixture containing equal amounts of two thermoplastic copolyether ester elastomers, for a weighted average of 45 weight percent short-chain ester units, one thermoplastic copolyether ester elastomer may contain 60 weight percent short-chain ester units, while the other resin may contain 30 weight percent short-chain ester units.

[0055] With respect to the properties of thermoplastic elastomers, it may be desirable to have a melt flow that allows them to be processed in a relatively easy manner for the formation of filaments and threads as disclosed herein. In this regard, thermoplastic elastomers may exhibit a relatively low melt viscosity, as indicated by the melt flow rate. For example, the melt flow rate of a thermoplastic elastomer may be about 0.5 g / 10 min or more, for example about 1 g / 10 min or more, for example about 2 g / 10 min or more, for example about 3 g / 10 min or more, for example about 4 g / 10 min or more, for example about 5 g / 10 min or more, for example about 8 g / 10 min or more, for example about 10 g / 10 min or more, for example about 15 g / 10 min or more, etc. The melt flow rate may be approximately 40 g / 10 min or less, for example approximately 35 g / 10 min or less, for example approximately 30 g / 10 min or less, for example approximately 25 g / 10 min or less, for example approximately 20 g / 10 min or less, for example approximately 15 g / 10 min or less, for example approximately 10 g / 10 min or less, for example approximately 8 g / 10 min or less, for example approximately 6 g / 10 min or less, for example approximately 5 g / 10 min or less, for example approximately 4 g / 10 min or less, for example approximately 3 g / 10 min or less, etc. The melt flow rate can be measured at 220°C under a load of 2.16 kg according to ISO 1133.

[0056] Thermoplastic elastomers may also have relatively low melting temperatures. For example, the melting temperature may be about 100°C or higher, e.g., about 110°C or higher, e.g., about 130°C or higher, e.g., about 150°C or higher, e.g., about 170°C or higher, e.g., about 190°C or higher, e.g., about 200°C or higher, e.g., about 220°C or higher, e.g., about 240°C or higher. The melting temperature may be about 300°C or lower, e.g., about 280°C or lower, e.g., about 250°C or lower, e.g., about 230°C or lower, e.g., about 210°C or lower, e.g., about 200°C or lower, e.g., about 180°C or lower, e.g., about 160°C or lower, e.g., about 140°C or lower, e.g., about 120°C or lower. The melting temperature may be measured using means known in the art, such as differential scanning calorimetry according to ISO 11357-1:2023 at a rate of 10°C / min.

[0057] In addition, the glass transition temperature of the thermoplastic elastomer, particularly the thermoplastic copolyester elastomer, 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, etc. The glass transition temperature can 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, etc. Also, the glass transition temperature of the hard segment of the thermoplastic copolyester elastomer can 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, etc. 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, etc. The glass transition temperature can be measured using known means in the art, such as differential scanning calorimetry, in accordance with ISO 11357-1:2023 at a rate of 10°C / min.

[0058] Furthermore, the thermoplastic elastomer can have a specific density. For example, the density can be about 1 g / cm 3 or higher, such as about 1.03 g / cm 3 or higher, such as about 1.05 g / cm 3 or higher, such as about 1.08 g / cm 3 or higher, such as about 1.1 g / cm 3 or higher, such as about 1.15 g / cm 3 or higher, such as about 1.2 g / cm 3 or higher, such as about 1.3 g / cm 3 or higher, etc. The thermoplastic elastomer can be about 2 g / cm 3 or lower, such as about 1.8 g / cm3 For example, approximately 1.6 g / cm³ 3 For example, approximately 1.4 g / cm³ 3 For example, approximately 1.3 g / cm³ 3 For example, approximately 1.25 g / cm³ 3 For example, approximately 1.2 g / cm³ 3 For example, approximately 1.18 g / cm³ 3 For example, approximately 1.15 g / cm³ 3 For example, approximately 1.12 g / cm³ 3 For example, approximately 1.1 g / cm³ 3 It may have densities such as those listed below. Density can be measured according to ISO 1183-1:2019.

[0059] A thermoplastic elastomer composition may generally contain one or more thermoplastic elastomers in amounts of about 10% by weight or more, for example, about 15% by weight or more, for example, about 20% by weight or more, for example, about 25% by weight or more, for example, about 30% by weight or more, for example, about 35% by weight or more, for example, about 40% by weight or more, for example, about 50% by weight or more, for example, about 60% by weight or more, for example, about 70% by weight or more, for example, about 80% by weight or more, for example, about 90% by weight or more, for example, about 95% by weight or more. A thermoplastic elastomer composition may contain one or more thermoplastic elastomers in amounts of about 100% by weight or less, for example, about 95% by weight or less, for example, about 90% by weight or less, for example, about 80% by weight or less, for example, about 70% by weight or less, for example, about 60% by weight or less, for example, about 50% by weight or less.

[0060] B. Additives In addition to thermoplastic elastomers, thermoplastic elastomer compositions may optionally further contain one or more additives. In this regard, in one embodiment, a thermoplastic copolyester elastomer composition may further contain one or more additives. For example, the additives may include those typically used in the art to provide a material having desired properties. These additives 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 phenolic, phosphite, and / or amine-containing antioxidants), viscosity modifiers, nucleating agents, lubricants, flow-promoting additives, flame retardants (e.g., phosphates such as polyphosphates and pyrophosphates; phosphinates, etc.), impact modifiers, antistatic agents, antimicrobial agents, colorants, pigments, etc.

[0061] When used, each additive may be present in the thermoplastic elastomer composition in amounts such as approximately 0.01% by weight or more, for example, approximately 0.05% by weight or more, for example, approximately 0.1% by weight or more, for example, approximately 0.2% by weight or more, for example, approximately 0.3% by weight or more, for example, approximately 0.5% by weight or more, for example, approximately 0.8% by weight or more, for example, approximately 1% by weight or more, for example, approximately 1.5% by weight or more, for example, approximately 2% by weight or more, for example, approximately 2.5% by weight or more, for example, approximately 3% by weight or more, for example, approximately 5% by weight or more, based on the weight of the thermoplastic elastomer composition. Each additive may be present in the thermoplastic elastomer composition in amounts such as about 20% by weight or less, for example, about 15% by weight or less, for example, about 12% by weight or less, for example, about 10% by weight or less, for example, about 8% by weight or less, for example, about 6% by weight or less, for example, about 5% by weight or less, for example, about 4% by weight or less, for example, about 3% by weight or less, for example, about 2.8% by weight or less, for example, about 2.5% by weight or less, for example, about 2.3% by weight or less, for example, about 2% by weight or less, for example, about 1.8% by weight or less, for example, about 1.6% by weight or less, for example, about 1.4% by weight or less, for example, about 1.2% by weight or less, for example, about 1% by weight or less, for example, about 0.8% by weight or less, for example, about 0.5% by weight or less, based on the weight of the thermoplastic elastomer composition. In another embodiment, the aforementioned weight percentages may be based on the weight of one or more thermoplastic elastomers.

[0062] In one embodiment, the thermoplastic elastomer composition may contain 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.

[0063] In this regard, non-elastomeric polymers include poly(meth)acrylic, polyacrylate, polystyrene, polyolefin (e.g., polyethylene such as high-density polyethylene, low-density polyethylene, linear low-density polyethylene, ultra-low-density polyethylene; polypropylene, etc.), polyurethane, polyurea, epoxy resin, polyester (e.g., poly(ethylene terephthalate), poly(1,3-propyl terephthalate), poly(1,4-butylene terephthalate), PETG, poly(ethylene-co-1,4-cyclohexanedimethanol terephthalate)), alkyd resin, polyamide (e.g., nylon, nylon 6, nylon 46, nylon 66, nylon 612), polyamide-imide, polyvinyl, phenoxy resin, amino resin, Examples include, but are not limited to, melamine, polyethers, polyvinyl acetal, polyvinyl formal, poly(vinyl butyrate), polyacetylene, polyethers, silicone resins, ABS resins, polysulfones, polyamine sulfones, polyethersulfones, polyphenylene sulfones, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyvinyl alcohol, polyvinylcarbazole, butyral, polyphenylene oxide, polypyrrole, polyparaphenylene, cellulose derivatives, polytetrafluoroethylene, polytrifluoroethylene, polyvinylidene fluoride, novolac, poly(cresol), polycarbonate, polysulfide, poly(phenylene sulfide), poly(2,6-dimethylphenylene oxide), etc. It should be understood that such non-elastomeric polymers may also include any of the above and their copolymerization. In addition, it should be understood that compositions may include combinations of two or more of the above. In one embodiment, the non-elastomeric polymer may be miscible with thermoplastic elastomer copolymers and / or thermoplastic elastomer polymer compositions.

[0064] If non-elastomeric polymers are present in a thermoplastic elastomer composition, they may be present in any amount. However, in one embodiment, they may be present in amounts less than the thermoplastic elastomer.

[0065] Non-elastomeric polymers may be present in the thermoplastic elastomer composition in amounts of about 1% by weight or more, for example, about 2% by weight or more, for example, about 5% by weight or more, for example, about 10% by weight or more, for example, about 15% by weight or more, for example, about 20% by weight or more, for example, about 25% by weight or more, for example, about 30% by weight or more, for example, about 35% by weight or more, for example, about 40% by weight or more, based on the total weight of the thermoplastic elastomer composition. Non-elastomeric polymers may be present in amounts of about 60% by weight or less, for example, about 50% by weight or less, for example, about 40% by weight or less, for example, about 35% by weight or less, for example, about 30% by weight or less, for example, about 25% by weight or less, for example, about 20% by weight or less, for example, about 15% by weight or less, for example, about 10% by weight or less, for example, about 8% by weight or less, for example, about 5% by weight or less, based on the total weight of the thermoplastic elastomer composition.

[0066] C. Composition formation The thermoplastic elastomer compositions described herein can be processed using techniques generally known in the art. For example, the components (thermoplastic elastomers and optional additives) can be melt-mixed (also known as melt-blending). Using such an approach, the components can be well dispersed throughout the composition. Furthermore, the components can be supplied in a single-step addition or in steps. The processing can be carried out in a chamber, which can be any container suitable for blending the composition under the required 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 reverse-rotating extruder, or a twin-screw extruder, a co-kneader such as a Buss® kneader, etc. Upon completion of mixing / blending, the composition can be crushed, shredded, extruded, pelletized, or processed by any other preferred technique. In certain examples, the components can be melt-blended and fed directly to downstream operations such as spinnerets to form filaments and yarns as disclosed herein. In particular, once formed, thermoplastic elastomer compositions can be used to form filaments and threads as further described herein.

[0067] II. Filaments and threads As shown herein, thermoplastic elastomer compositions are suitable for forming filaments and corresponding yarns. While thermoplastic elastomer compositions can be used to form short-fiber yarns, in a particular embodiment, thermoplastic elastomer compositions are used to form continuous filaments and corresponding yarns. In particular, the properties of thermoplastic elastomers allow them to be processed to form filaments at speeds and conditions as disclosed herein, and then the filaments to be processed to form yarns and the resulting articles.

[0068] The filaments of this disclosure can be manufactured using conventional processes known in the art. For example, these processes may include general steps such as spinning a thermoplastic elastomer composition, including a thermoplastic elastomer, and optionally stretching it into a filament. The filaments may also be treated mechanically and / or chemically (e.g., via a finishing agent) to impart desirable properties such as strength, elasticity, heat resistance, feel, etc., depending on the desired properties and characteristics of the articles produced from the filaments and yarns.

[0069] In a particular embodiment, the filament may be formed by melt spinning. Thus, the filament may be a melt-spun filament. Generally, melt spinning involves heating a thermoplastic elastomer composition, including a thermoplastic elastomer, to form a melt (also called an elastomer melt), where such melting can be achieved by heating the thermoplastic elastomer in contact with a heated surface. As an example, the thermoplastic elastomer may be heated in a mixer or extruder and then supplied to a spinneret or metered and fed. The operating temperature may correspond to the melting temperature of the thermoplastic elastomer; for example, to enable the formation of an elastomer melt, the temperature may be relatively higher than the melting temperature of the thermoplastic elastomer. In any case, the operating temperature may be within the range of the melting temperature of the thermoplastic elastomer as defined above.

[0070] A spinneret comprises multiple orifices or capillaries of specific sizes and designs that enable the formation of filaments having a desired configuration and cross-section. Thus, this process allows for the formation of filaments of various sizes and cross-sections, such as filaments having circular, elliptical, square, rectangular, lobe-shaped, or dogbone-shaped cross-sections. Plates of specific designs used to manufacture filaments can be formed using means known in the art, such as laser cutting, micro-hole drilling, laser micro-machining, and micro-wire EDM. Furthermore, it should be understood that pre-bonded (e.g., forming a desired cross-section through the spinneret capillaries) or post-bonded (e.g., allowing the molten material to bond beneath the spinneret surface to form a desired cross-section) spinnerets can be used.

[0071] In this regard, any monofilament used in the manufacture of any multifilament herein may be a pre-combined monofilament or a post-combined monofilament. In a particular embodiment, the monofilament may be a post-combined monofilament in which individual filaments combine as they exit or are pulled out of the spinneret. To enable such combination, the filaments may still be at a temperature higher than the melting temperature of the thermoplastic elastomer, thereby enabling such filaments to combine (or fuse) for the formation of a monofilament, which can then be used to form a multifilament yarn. In any case, the multifilaments of the present disclosure are not combined or fused. In this regard, the filaments constituting a multifilament yarn are bonded and in contact with each other at a temperature lower than the melting temperature of the thermoplastic elastomer so that they cannot have the ability to combine or fuse. Such filaments constituting a multifilament yarn may be bonded and in contact with each other, where the filaments are at a temperature higher than the glass transition temperature of the thermoplastic elastomer. In this regard, the filaments may have a general tackiness that enables such bonding between filaments of a multifilament yarn, without being intended to be limited by theory.

[0072] 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 a liquid (e.g., water) to aid in its solidification. As an example, the filament can be quenched using a non-reactive gas stream, such as air, while traversing in a general vertical direction. In another embodiment, the filament can be quenched while traversing in a relatively horizontal direction through a liquid. In addition, in one embodiment, additional quenching may not be necessary, and sufficient quenching may be performed based on ambient conditions. The filament can then be collected downstream from the spinneret using a guide and wound onto a roller or a series of rollers.

[0073] Thermoplastic elastomers can be spun at speeds of approximately 200 to approximately 6000 meters per minute (m / min), depending on the desired filament size. When forming filaments, the spinning speed can be at least approximately 200 m / min, for example at least approximately 400 m / min, for example at least approximately 500 m / min, for example at least approximately 600 m / min, for example at least approximately 800 m / min, for example at least approximately 1000 m / min, for example at least approximately 2000 m / min, and so on. The spinning speed may be approximately 6000 m / min or less, for example approximately 5000 m / min or less, for example approximately 4000 m / min or less, for example approximately 3000 m / min or less, for example approximately 2500 m / min or less, for example approximately 2000 m / min or less, for example approximately 1800 m / min or less, for example approximately 1600 m / min or less, for example approximately 1400 m / min or less, for example approximately 1200 m / min or less, for example approximately 1000 m / min or less, etc.

[0074] In addition, finishing agents may be applied to the filament. Finishing agents may be applied to facilitate spinning and / or subsequent processing. For example, finishing agents may be applied to provide lubrication, thereby minimizing friction. Finishing agents generally include oils (finishing oils). In this regard, finishing oils may include, but are not limited to, silicone oils, mineral oils, ester oils, and mixtures thereof. In one embodiment, the finishing oil may include a silicone oil. In another embodiment, the finishing oil may include a mineral oil. In a further embodiment, the finishing oil may include an ester oil. However, it should be understood that other finishing oils used for thermoplastic elastomers may also be used. In addition, finishing agents may also include other additives commonly used in the art. In this regard, finishing agents may include salts of fatty acids, in particular metal salts of fatty acids. For example, the fatty acid salt may be a stearate in one embodiment. 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.

[0075] Such application of a finishing agent may be performed before stretching the unstretched filament when stretching such a filament. In addition, it may be performed after quenching. In one embodiment, such application may be performed during quenching; in such a case, the filament and / or yarn may have crimp, such as helical crimp.

[0076] The finishing agent may be provided on the yarn in a specific amount. For example, the amount of finishing agent on the yarn may be about 1% by weight or more, for example about 2% by weight or more, for example about 3% by weight or more, for example about 4% by weight or more, for example about 5% by weight or more, for example about 6% by weight or more, for example about 7% by weight or more, for example about 8% by weight or more, for example about 9% by weight or more, etc., based on the total weight of the yarn. The amount of finishing agent on the yarn may be about 20% by weight or less, for example about 18% by weight or less, for example about 16% by weight or less, for example about 14% by weight or less, for example about 12% by weight or less, for example about 11% by weight or less, for example about 10% by weight or less, for example about 9% by weight or less, for example about 8% by weight or less, for example about 7% by weight or less, for example about 6% by weight or less, for example about 5% by weight or less, etc., based on the total weight of the yarn. In addition, the finishing agent may be provided on at least about 50% of the surface area of ​​the filament. For example, a finishing agent may be applied to at least about 50% of the filament's surface area, e.g., at least about 55%, e.g., at least about 60%, e.g., at least about 65%, e.g., at least about 70%, e.g., at least about 75%, e.g., at least about 80%, e.g., at least about 85%, e.g., at least about 90%, e.g., at least about 95%. In addition, a finishing agent may be applied to at least about 50% of the filament's surface area. For example, a finishing agent may be applied to at least about 50% of the filament's surface area, e.g., at least about 55%, e.g., at least about 60%, e.g., at least about 65%, e.g., at least about 70%, e.g., at least about 75%, e.g., at least about 80%, e.g., at least about 85%, e.g., at least about 90%, e.g., at least about 95%, etc. Without being intended to be limited by theory, such a finishing agent may help the filaments in a multifilament yarn. The amount of finishing agent on the yarn can be determined by using techniques known in the art, in particular by monitoring the filament speed and the metered amount of finishing agent on the filament.

[0077] After extrusion from the spinneret, the filament may be stretched. Stretching can help achieve desirable properties such as increased amorphous orientation, shrinkage, modulus of elasticity, and / or strength. However, it should be understood that in certain embodiments, stretching may not be performed so that the resulting filament is an unstretched filament. In such embodiments, the filament may still, nevertheless, have certain desirable properties. If stretching is performed, it may be done in combination with winding by using a series of rollers or pins, some of which may generally be heated, or it may be done as a separate step in the filament formation process. If heated, stretching may be carried out at temperatures such as about 15°C to 150°C, e.g., about 15°C to 130°C, e.g., about 15°C to 100°C, e.g., about 15°C to 80°C, e.g., about 15°C to 60°C, e.g., about 15°C to 40°C, etc.

[0078] Godet roll speeds, which can typically be used between the feed roll and the winding roll, and for stretching under certain conditions, can range from about 200 to about 6000 meters per minute (m / min). For example, this speed could be at least about 200 m / min, for example at least about 400 m / min, for example at least about 500 m / min, for example at least about 600 m / min, for example at least about 800 m / min, for example at least about 1000 m / min, for example at least about 1250 m / min, for example at least about 1500 m / min, for example at least about 1750 m / min, for example at least about 2000 m / min, and so on. This speed could be approximately 6000 m / min or less, for example approximately 5000 m / min or less, for example approximately 4000 m / min or less, for example approximately 3000 m / min or less, for example approximately 2750 m / min or less, for example approximately 2500 m / min or less, for example approximately 2250 m / min or less, for example approximately 2000 m / min or less, for example approximately 1800 m / min or less, for example approximately 1600 m / min or less, for example approximately 1400 m / min or less, for example approximately 1200 m / min or less, for example approximately 1000 m / min or less, and so on.

[0079] The filament can be stretched to any desired stretch ratio depending on the desired properties, except for any factors that would hinder processing by causing the filament to break. In this regard, the filament can be stretched from 0× to about 6×, for example, about 0.9× to about 6×, for example, about 1.1× to about 6×, etc. For example, the filament can be stretched to 0× or more, for example, at least about 0.2×, for example, at least about 0.3×, for example, at least about 0.5×, for example, at least about 0.7×, for example, at least about 0.9×, for example, at least about 1.1×, for example, at least about 1.2×, for example, at least about 1.3×, for example, at least about 1.4×, for example, at least about 1.5×, for example, at least about 1.8×, for example, at least about 2×, for example, at least about 2.2×, for example, at least about 2.4×, for example, at least about 2.5×, etc. The filament can be stretched to approximately 5× or less, for example, approximately 4.5× or less, for example, approximately 4× or less, for example, approximately 3.5× or less, for example, approximately 3× or less, for example, approximately 2.8× or less, for example, approximately 2.6× or less, for example, approximately 2.4× or less, for example, approximately 2.2× or less, for example, approximately 2× or less, etc. Such stretching may be performed in a single-step stretching in one embodiment. However, in another embodiment, the filament may not be stretched at all.

[0080] The resulting filament is also suitable for further processing using additional processing equipment, or it can be used directly in applications requiring continuous filaments and / or yarn. Regarding further processing, the filament can then be converted into a textured yarn by known false-twist texture processing conditions or other processes. Increasing the surface area of ​​the filament to provide a softer feel and enhancing the filament's ability to easily pass air, thereby providing better thermal insulation and water retention in the case of textiles, may also be desirable. To increase the surface area, the filament may be crimped or twisted, for example, by false-twist methods, air jets, edge crimping, gear crimping, stuffer boxes, etc. In the case of elastomeric yarn, a "bulking" type process may also be performed to heat the yarn with minimal tension to allow the yarn to relax and shrink, which can increase the elongation at break and thermal stability through the yarn's thermal history. The method used may be determined by the specific application of the filament.

[0081] In addition, after formation, the filaments may be treated by any method appropriate for the desired end use. For example, particularly with respect to textiles, this may include dyeing, coloring with pigments, sizing, or the addition of chemical agents such as antistatic agents, flame retardants, UV light stabilizers, antioxidants, pigments, dyes, stain-resistant agents, and / or antimicrobial agents. In addition, the filaments may be treated to impart additional desired properties such as strength, elasticity, or shrinkage. It should be understood that while filaments and yarns may be treated using such techniques, the resulting articles may also be treated using such techniques. Nevertheless, examples of preferred treatment and application methods can be found in "Textile coloration and finishing" by Warren S. Perkins, Carolina Academic Press, Durham, NC, 1996.

[0082] Therefore, generally, a method for producing a filament as disclosed herein may include at least the following: extruding a molten material comprising a thermoplastic copolyester elastomer composition containing a thermoplastic copolyester elastomer through a spinneret; pulling a filament from the spinneret; and collecting the filament on a winding roller. In addition, the method may also include quenching the filament using air. Such quenching may be performed before stretching the filament, if stretching is to be performed. The method may also include applying a finishing agent to the filament. Such application may also be performed before stretching the filament, if stretching is to be performed; in addition, it may be performed after quenching. The method may also include the step of stretching the filament using a stretching roller. Such stretching may be performed after quenching and / or after application of the finishing agent.

[0083] Furthermore, generally, a method for producing a multifilament yarn as disclosed herein may include at least the following: extruding a molten material containing a thermoplastic elastomer composition containing a thermoplastic elastomer through a spinneret; pulling out a first filament and a second filament from the spinneret; and collecting the first filament and the second filament on a winding roller. If a third filament (or more) is present, the above steps may be the same for forming the third filament. In addition, the method may also include quenching the first and second filaments using air. Such quenching may be performed before stretching the filaments if stretching is performed; in addition, it may be performed after quenching. If present, the application of the finishing agent may also be performed with respect to the third filament. Furthermore, the method may include a step of stretching the first and second filaments using a stretching roller. Such stretching may be performed after quenching and / or after the application of a finishing agent. The method may also include a step of stretching a third filament, if present. In addition, the method for producing multifilament yarn may also include a step of converging the filaments to form a multifilament yarn.

[0084] Furthermore, a melt spinning process for spinning filaments, particularly continuous filaments, is also disclosed in accordance with this disclosure. In this regard, the process is described in reference to Figure 1. Generally, Figure 1 is a schematic diagram of an apparatus that can be used to manufacture filaments as disclosed herein. However, it should be understood that other apparatus may also be used in accordance with this disclosure.

[0085] Generally, the process involves passing a molten material containing a thermoplastic elastomer composition, including a thermoplastic elastomer, through a spinneret to form a plurality of stretchable, synthetic elastomeric filaments. With respect to Figure 1, a thermoplastic elastomer composition feed (in other forms, e.g., granular form, pellet form, or molten material, etc.) is introduced into the spinneret 2 at 1. The molten filaments are extruded through the spinneret. The elastomer can be extruded as an undrawn filament 4 from the spinneret 2, which has an orifice designed to give a desired cross-section. In addition, the process may further include quenching the filaments after they have exited the capillary of the spinneret to cool and / or solidify the filaments by any known method, for example, by cold air at 3 in Figure 1. The figure shows cross-flow quenching, where air is provided from a direction traversing the direction of filament formation. However, any preferred quenching method, such as in-flow quenching, out-flow quenching, and / or radial-flow quenching, may be used.

[0086] The filaments can be treated with finishing agents as defined herein using any known technique with finishing agent applicators 5a, 5b as shown in Figure 1. Generally, the application of the finishing agent may be a roll finishing agent application 5a or a metered feeding finishing agent application 5b. These filaments can then be stretched as needed after quenching. The filaments can be stretched in at least one stretching step to form a stretched filament 8, for example, between a feed roll 6 (which can be operated at 150-1000 m / min) and a stretching roll 7, schematically shown in Figure 1. The stretching step may be combined with spinning to produce a stretched yarn. Stretching can also be achieved while winding the filaments as warp threads of a yarn, which is called a “stretched warp.” In this specification, the stretching ratio may be the stretching roll 7 speed divided by the feed roll 6 speed.

[0087] The filament 8, which may or may not be optionally stretched, can be partially relaxed with steam, for example, in Figure 1, 9. Any amount of thermal relaxation can be carried out during spinning. In connection therewith, the filament can be dry or wet heat treated while relaxed to exhibit desired elasticity and recovery properties. Such relaxation can be achieved during filament production, for example, during the relaxation step described above, or after the filament has been incorporated into a yarn or fabric, for example, during sculling, dyeing, etc. Heat treatment of the filament or yarn form can be carried out, for example, using a hot roll or hot chest, or in a jet screen bulking step. Such relaxation heat treatment may be preferable to be carried out after the filament is in a yarn or fabric so that it can be processed like a non-elastomeric filament until then; however, if necessary, it can be heat treated and fully relaxed before being wound as a filament. For greater uniformity in the final fabric, the filament can be uniformly heat treated and relaxed. The heat treatment / relaxation temperature can range from approximately 80°C to 150°C when the heating medium is dry air or steam, from approximately 75°C to 100°C when the heating medium is hot water, and from approximately 101°C to 115°C when the heating medium is ultra-atmospheric pressure steam. 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 generally be achieved in a few seconds. Without intending to limit, generally, the greater the relaxation, the more elastic the filament becomes, resulting in less shrinkage that may occur in downstream operations. In addition, without intending to limit, such treatment may also allow the resulting articles (e.g., clothing), fabrics, and / or yarns to be thermally stable for post-processing processes such as screen printing, sublimation dyeing, etc.

[0088] In addition, filament relaxation can be achieved by utilizing rolls / rollers present in the process. For example, as disclosed herein, the process may include a feed roller from which the filament can be drawn out of the spinneret. The process may also include a draw roller or godet roller after the feed roller. Finally, the filament / yarn can be wound by a winding roller. By controlling the speed of each roller, the filament and / or yarn may have the opportunity to relax. For example, in one embodiment, the feed roller speed may be faster than the draw roller speed, or, if there is no draw, the godet roller speed. In one embodiment, the draw roller speed, or, if there is no draw, the godet roller speed, may be faster than the winding roller speed. In further embodiments, the feed roller speed may be faster than the draw roller speed, or, if there is no draw, the godet roller speed, and the draw roller speed, or, if there is no draw, the godet roller speed, may be faster than the winding roller speed.

[0089] The filaments, which are then rapidly cooled, optionally stretched, and optionally relaxed, can be collected by winding them onto the winding machine 11 shown in Figure 1. The winding machine may also be called a winding roll. The winding speed can be approximately 200 to approximately 6000 meters per minute (m / min). For example, the winding speed may be at least approximately 200 m / min, for example at least approximately 400 m / min, for example at least approximately 500 m / min, for example at least approximately 600 m / min, for example at least approximately 800 m / min, for example at least approximately 1000 m / min, for example at least approximately 1250 m / min, for example at least approximately 1500 m / min, for example at least approximately 1750 m / min, for example at least approximately 2000 m / min, and so on. The winding speed may be approximately 6000 m / min or less, for example approximately 5000 m / min or less, for example approximately 4000 m / min or less, for example approximately 3000 m / min or less, for example approximately 2750 m / min or less, for example approximately 2500 m / min or less, for example approximately 2250 m / min or less, for example approximately 2000 m / min or less, for example approximately 1800 m / min or less, for example approximately 1600 m / min or less, for example approximately 1400 m / min or less, for example approximately 1200 m / min or less, for example approximately 1000 m / min or less, etc.

[0090] In one embodiment, the winding speed may be slower than the stretching (or godet) roll speed. For example, the stretching (or godet) roll speed may be 75% or more of the winding speed, e.g., 80% or more, e.g., 85% or more, e.g., 88% or more, e.g., 90% or more, e.g., 92% or more, e.g., 94% or more, e.g., 95% or more, e.g., 96% or more, e.g., 97% or more, e.g., 97.5% or more, e.g., 98% or more, e.g., 98.5% or more, e.g., 99% or more but less than 100%, etc. Without intending to be limited by theory, it is thought that such a difference in speed may allow the filament and yarn to have an opportunity to relax at least partially.

[0091] When multiple filaments are spun and quenched, the filaments can be converged, optionally intertwined, and then wound. For example, such convergence and / or intertwining may be performed to form a multifilament yarn. Single filament or multifilament yarns can similarly be wound on the winding machine 11 in Figure 1. When multiple filaments are spun and quenched, the filaments can be converged and optionally entangled before winding, as is done in the art. Convergence can occur at multiple points in the process. For example, convergence may occur at the feed roll or in front of the feed roll, such as in a finishing applicator.

[0092] As described herein, filaments may be used to manufacture yarn. Yarn may include, but is not limited to, a number of filaments twisted together (spun yarn), a number of filaments placed together without twisting (zero-twist yarn), and a number of filaments placed together with some degree of twist.

[0093] In one embodiment, the multifilament yarn disclosed herein may not have any twist. In another embodiment, the multifilament yarn disclosed herein may have a relatively small amount of twist. For example, the twist may be 1 or less per inch, for example 0.9 or less per inch, for example 0.8 or less per inch, for example 0.7 or less per inch, for example 0.6 or less per inch, for example 0.5 or less per inch, for example 0.4 or less per inch, for example 0.3 or less per inch, for example 0.2 or less per inch, for example 0.1 or less per inch, for example 0.05 or less per inch, for example 0.01 or less per inch, and so on. The twist can be 0 or more twists per inch, for example 0.01 or more twists per inch, for example 0.05 or more twists per inch, for example 0.1 or more twists per inch, for example 0.2 or more twists per inch, for example 0.3 or more twists per inch, for example 0.4 or more twists per inch, for example 0.5 or more twists per inch, and so on.

[0094] In addition, multifilament yarns may have minimal entanglement. For example, an entangled yarn may be characterized by points of entanglement called nodes, which are separated by spaces of unentangled filaments. In this regard, the distance between the end of a first node and the beginning of a second node for a multifilament yarn as disclosed herein may be relatively long. In addition, the average distance between nodes of a multifilament yarn may be relatively long. For example, the distance may be about 1 or more inches, for example about 2 or more inches, for example about 3 or more inches, for example about 4 or more inches, for example about 5 or more inches, for example about 6 or more inches, for example about 8 or more inches, for example about 10 or more inches, for example about 12 or more inches, for example about 16 or more inches, for example about 20 or more inches, for example about 24 or more inches, for example about 30 or more inches, for example about 36 or more inches, for example about 42 or more inches, for example about 48 or more inches, for example about 54 or more inches, for example about 60 or more inches, and so on.

[0095] As shown herein, yarns can generally have any filament count to form a multifilament yarn. For example, a yarn is a multifilament yarn formed from two or more filaments, where such two or more filaments may be wound to form a yarn. Thus, a multifilament yarn includes a first filament that is at least partially bonded to a second filament. In addition, a multifilament yarn may further include a third filament, where the third filament is at least partially bonded 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, where such filaments are at least partially bonded to each other. In this regard, in one embodiment, such filaments may simply bond to each other, where such bonding points between filaments do not have to be fusions, which are defined as combining or linking filaments at a temperature above the polymer melting temperature.

[0096] In this regard, a multifilament yarn may contain at least about two filaments. A multifilament yarn may contain about two or more filaments, for example, about three or more, for example, about five or more, for example, about ten or more, for example, about fifteen or more, for example, about 20 or more, for example, about 25 or more, for example, about 50 or more, for example, about 100 or more. A multifilament yarn may contain about 200 or fewer filaments, for example, about 100 or fewer, for example, about 80 or fewer, for example, about 60 or fewer, for example, about 50 or fewer, for example, about 40 or fewer, for example, about 35 or fewer, for example, about 30 or fewer, for example, about 25 or fewer, for example, about 20 or fewer, for example, about 15 or fewer, for example, about 10 or fewer, for example, about 5 or fewer, for example, about 4 or fewer, for example, about 3 or fewer, and so on.

[0097] The yarn may have a total denier of approximately 1 to approximately 2000. For example, the total denier may be approximately 1 or more, for example approximately 5 or more, for example approximately 10 or more, for example approximately 20 or more, for example approximately 30 or more, for example approximately 40 or more, for example approximately 50 or more, for example approximately 70 or more, for example approximately 100 or more, for example approximately 120 or more, for example approximately 140 or more, for example approximately 160 or more, for example approximately 180 or more, for example approximately 200 or more, for example approximately 300 or more, for example approximately 500 or more, for example approximately 800 or more, for example approximately 1000 or more, for example approximately 1300 or more, for example approximately 1500 or more, for example approximately 1800 or more, for example approximately 2000 or more, etc. The total denier may be approximately 3000 or less, e.g., approximately 2800 or less, e.g., approximately 2500 or less, e.g., approximately 2200 or less, e.g., approximately 2000 or less, e.g., approximately 1800 or less, e.g., approximately 1600 or less, e.g., approximately 1400 or less, e.g., approximately 1200 or less, e.g., approximately 1000 or less, e.g., approximately 800 or less, e.g., approximately 600 or less, e.g., approximately 500 or less, e.g., approximately 450 or less, e.g., approximately 400 or less, e.g., approximately 350 or less, e.g., approximately 300 or less, e.g., approximately 275 or less, e.g., approximately 250 or less, e.g., approximately 225 or less, e.g., approximately 200 or less, e.g., approximately 180 or less, e.g., approximately 160 or less, e.g., approximately 140 or less, e.g., approximately 120 or less, e.g., approximately 100 or less, e.g., approximately 80 or less, e.g., approximately 60 or less, e.g., approximately 50 or less, etc. The denier may be measured at a temperature of approximately 23°C according to D2259-02(2016).

[0098] In addition, the yarn may have a specific linear density such that it is related to the filaments that make up the yarn. For example, the yarn may have at least about 0.1 denier (dpf) per filament, for example at least about 0.2 dpf, for example at least about 0.5 dpf, for example at least about 0.7 dpf, for example at least about 1 dpf, for example at least about 2 dpf, for example at least about 3 dpf, for example at least about 4 dpf, for example at least about 5 dpf, for example at least about 8 dpf, for example at least about 10 dpf, for example at least about 20 dpf, for example at least about 30 dpf, for example at least about 50 dpf, for example at least about 70 dpf, for example at least about 90 dpf, for example at least about 110 dpf, for example at least about 130 dpf, for example at least about 150 dpf, and so on. The thread is approximately 500 dpf or less, for example approximately 450 dpf or less, for example approximately 400 dpf or less, for example approximately 350 dpf or less, for example approximately 300 dpf or less, for example approximately 250 dpf or less, for example approximately 200 dpf or less, for example approximately 180 dpf or less, for example approximately 150 dpf or less, for example 130 dpf or less, for example 110 dpf or less, for example 100 dpf or less, for example 90 dpf or less, for example 80 dpf or less, for example 70 dpf or less, for example 60 dpf or less, for example 50 dpf or less, for example approximately 40 The following dpf values ​​may be present, for example, about 35 dpf or less, about 30 dpf or less, about 25 dpf or less, about 22 dpf or less, about 20 dpf or less, about 18 dpf or less, about 16 dpf or less, about 14 dpf or less, about 12 dpf or less, about 10 dpf or less, about 8 dpf or less, about 6 dpf or less, about 5 dpf or less, about 4 dpf or less, about 3.5 dpf or less, about 3 dpf or less, about 2.5 dpf or less, etc. Without being intended to limit, the dpf may be relatively lower for a particular application than for other applications. For example, the dpf may be relatively lower for textile applications than for industrial applications. In any case, the size and strength of such filaments can be easily measured using means generally known in the art.

[0099] As shown herein, a filament may have a specific cross-section, such as that determined by the spinneret design. Generally, a filament may have an axial core extending along the continuous length direction of the filament. In this regard, the axial core may, in one embodiment, comprise a thermoplastic elastomer as defined herein. In another embodiment, the axial core of the filament may be hollow, such that it does not comprise a thermoplastic elastomer or composition as defined herein.

[0100] In one embodiment, the filament may generally have a circular cross-section. In another embodiment, the filament may generally have a non-circular cross-section. For example, the filament may generally have an oval cross-section. However, it should be understood that other non-circular cross-sections may also be formed from thermoplastic elastomers as disclosed herein.

[0101] In another embodiment, the filament may be multilobed. For example, the filament may contain two or more lobes. Such lobes may be arranged radially from an axial core. In this regard, the lobes may extend from the central portion of the filament or from the axial core, where each lobe has a proximal end adjacent to the central portion and a distal end spaced radially away from the proximal end. Furthermore, each lobe may have a convex surface. In this regard, each lobe does not have to include a relatively flat surface.

[0102] Furthermore, in one embodiment, each lobe may be directly connected to one another. In this regard, such connection points between adjacent lobes may be called cusps. Alternatively, adjacent lobes may not be directly connected. Such a region connecting two adjacent lobes may be called a lobe connection. Such a lobe connection may also have a relatively convex surface. Similar to the lobes, such a lobe connection may also not include a relatively flat surface.

[0103] In addition, the lobes may be symmetrically arranged around the filament. In other words, the filament may have a symmetrical cross-section in one embodiment. In another embodiment, the filament may have an asymmetrical cross-section. Furthermore, the lobes may be asymmetrical or symmetrical. In one embodiment, the lobes may be asymmetrical. In another embodiment, the lobes may be symmetrical.

[0104] In one embodiment, the filament may have a core / sheath configuration. For example, the axial core may be formed of a thermoplastic elastomer composition as defined herein. Such a composition may be referred to as the first thermoplastic elastomer composition. In addition, the sheath may be formed of a second thermoplastic elastomer composition. Such a second thermoplastic elastomer composition may differ from the first thermoplastic elastomer composition in at least one embodiment. For example, even if both may contain thermoplastic elastomers as defined herein, the properties of each thermoplastic elastomer may differ. In this regard, the first thermoplastic elastomer composition may contain a first thermoplastic elastomer, and the second thermoplastic elastomer composition may contain a second thermoplastic elastomer, where the first thermoplastic elastomer is different from the second thermoplastic elastomer in at least one embodiment.

[0105] Furthermore, as shown herein, the filament may include two or more lobes arranged radially around an axial core. In this regard, the lobes may be formed from a second thermoplastic elastomer composition and a second thermoplastic elastomer. For example, the axial core may be formed from a first thermoplastic elastomer composition and a first thermoplastic elastomer, including the lobes, while the sheath may be formed from a second thermoplastic elastomer composition and a second thermoplastic elastomer.

[0106] Examples of various cross-sections of monofilaments are shown in Figures 2A, 2B, 3A, 3B, 3C, 4A, 4B, and 4C. For example, Figures 2A and 2B show cross-sections of two lobes, Figures 3A, 3B, and 3C show cross-sections of three lobes, and Figures 4A, 4B, and 4C show cross-sections of four lobes. Each cross-section and configuration includes lobes extending radially from the axial core of the filament.

[0107] Referring to Figures 2A and 2B, the filament 200 has a two-lobe cross-section. In particular, the filament 200 includes two lobes 210. In Figure 2A, the lobes 210 are directly connected to each other by a cusp 220. In Figure 2B, the lobes 210 are not directly connected to each other. In this regard, they are indirectly connected to each other via a lobe connector 230.

[0108] Referring to Figures 3A, 3B, and 3C, the filament 300 has a three-lobe cross-section. In particular, the filament 300 includes three lobes 310. In Figures 3A and 3C, the lobes 310 are directly connected to each other at the cusp 320. In Figure 3B, the lobes 310 are not directly connected to each other. In this regard, they are indirectly connected to each other via the lobe connector 330. In addition, in Figure 3C, the lobes 310 are joined at the cusp 320, providing a hollow core 340.

[0109] Referring to Figures 4A, 4B, and 4C, the filament 400 has a four-lobe cross-section. In particular, the filament 400 includes four lobes 410. In Figures 4A and 4C, the lobes 410 are directly connected to each other by cusps 420. In Figure 4B, the lobes 410 are not directly connected to each other. In this regard, they are indirectly connected to each other via lobe connectors 430. In addition, in Figure 3C, the lobes 410 are joined at cusps 420 while providing a hollow core 440.

[0110] Examples of various multifilament yarns are shown in Figures 2C, 5, and 6. For example, Figure 2C shows a two-filament multifilament yarn 2000. In particular, the multifilament yarn 2000 includes two individual filaments 2100 that are bonded to each other and do not necessarily converge. In connection with this, Figure 5 shows a three-filament multifilament yarn 3000. In particular, the multifilament yarn 3000 includes three individual filaments 3100 that are bonded to each other and do not necessarily converge. In addition, the multifilament yarn 3000 includes a hollow core 3400. Similarly, Figure 6 shows a four-filament multifilament yarn 4000. In particular, the multifilament yarn 4000 includes four individual filaments 4100 that are bonded to each other and do not necessarily converge. In addition, the multifilament yarn 4000 includes a hollow core 4400.

[0111] As shown in Figures 2C, 5, and 6, each individual filament in a multifilament yarn has a relatively circular cross-section. However, filaments with a non-circular cross-section, such as those shown in Figures 2A, 2B, 3A, 3B, 3C, 4A, 4B, and 4C, can be used to manufacture multifilament yarns for use in articles as disclosed herein.

[0112] III. Goods The inventors have found that the advantageous properties of filaments and yarns as disclosed herein can enable them to be used to form a variety of articles for a variety of applications. In this regard, filaments can be used to form yarns that can be used to prepare woven, knitted, and / or nonwoven articles that can be prepared using conventional techniques including, but not limited to, meltblown, spunbond, and card-and-bond, including thermal bonding (hot air and spot bonding), air entanglement, and other techniques. For example, they can be subjected to a variety of high-speed conditions for the formation of such articles.

[0113] In addition, the composition of the yarn may depend on the specific application. For example, the yarn may be used as bare yarn or coated yarn. In one embodiment, the yarn may be used as bare yarn itself. Alternatively, the yarn may be used as coated yarn, where the yarn described herein may be used as a core. For such coated yarn, an inelastic filament or yarn or short fiber yarn may wrap around the core, particularly in a spiral manner. In addition or instead, another elastic yarn may also be used for coating.

[0114] For example, yarn can be used for textile fabrics for clothing and household furniture. For instance, yarn may be elastic and may exhibit desired resilience, which may be desirable for such applications. In this regard, yarn can be used for textiles. In particular, yarn can be used to manufacture fabrics such as knitted or woven fabrics. As a result, yarn can be considered a knittable yarn, especially a knittable, elastic yarn.

[0115] The knitted structures of yarns are not necessarily limited by this disclosure. For example, various types of knitted structures known in the art may be used to form fabrics and / or articles made using filaments and yarns as disclosed herein. In particular, knitted structures may be those disclosed in U.S. Patent No. 9,689,092, U.S. Patent No. 10,370,782, or U.S. Patent Application Publication No. 2021 / 0254244, all of which are incorporated herein by reference in their entirety.

[0116] In a particular embodiment, the knitted structure may be a circular knitted structure. Without being intended to be limiting, articles formed from circular knitted fabrics may be more comfortable than other knitted structures, partly due to the fabric's ability to stretch. For example, when force is applied, a circular knitted fabric may stretch slightly due to compression and / or stretching that may occur between the stitches / loops of the fabric, and then recover.

[0117] Generally, knitting is the process of constructing a fabric by connecting a series of loops (bites) of one or more strands knitted in ridges and courses. Generally, knitting includes warp knitting and weft knitting. In warp knitting, multiple strands run longitudinally through the fabric to make up all the loops. In weft knitting, a single continuous strand runs transversely through the fabric to make up all the loops in one course. Weft knitting includes fabrics formed on both circular knitting machines and flat knitting machines. On a circular knitting machine, the fabric is produced in the form of a tube, with the strands running continuously around the fabric. On a flat knitting machine, the fabric is produced in a flat form, with the threads running alternately back and forth across the fabric. The resulting textile includes an inner surface (technical back) and an outer surface (technical face), with each layer formed from the same or varying strands and / or stitches. For example, knitted structures can be single-knit / jersey fabrics, double-knit / jersey fabrics, and / or plated fabrics (where yarns of different properties are arranged on the front and back surfaces).

[0118] The textile may be formed by weft knitting, in which case a single continuous thread runs transversely through the fabric, making up the entire loop in one course. Preferably, the weft-knitted textile is formed by circular knitting, in which case the textile is manufactured in the form of a tube, with the thread running continuously around the textile.

[0119] Referring to Figure 7, the textile has a knitted structure 500 made up of courses 505A, 505B, 505C and ridges 510A, 510B, 510C, where each course is formed by strands. The term “strand” includes monofilament (a continuous strand of textile filament in a form suitable for knitting, weaving, or otherwise twisting together to form a textile fabric). In one embodiment, the knitted structure 500 includes a first strand 515. As shown, the strand 515 forms a plurality of courses 505 and, in particular, a plurality of continuous courses 505 within the knitted structure 500. In one embodiment, in the knitted structure 500, at least one strand 515 may be formed from a thermoplastic elastomer yarn as disclosed herein. In one embodiment, all of the strands 515 in the knitted structure may be formed from a thermoplastic elastomer yarn as disclosed herein.

[0120] However, while this may be the case, it should be understood that other types of strands and yarns may also be available. For example, in one embodiment, in the knitted structure 500, at least one strand 515 may be another strand typically used in the art and may not be a thermoplastic elastomer yarn as disclosed herein. For example, in one embodiment, such a strand may be another type of elastic strand. These may include strands of anidex, elastoester, two-component filament rubber, and combinations thereof. As a specific example, elastane, manufactured fibers in which the fiber-forming material is a long-chain synthetic polymer consisting of at least 85% segmented polyurethane may be available. Alternatively, in one embodiment, such a strand may be an inelastic strand not typically formed of an elastomeric material. These strands may include natural fibers such as cellulose fibers (e.g., cotton, bamboo) and protein fibers (e.g., wool, silk, and soybeans), as well as synthetic fibers such as polyester fibers (poly(ethylene terephthalate) fibers and poly(trimethylene terephthalate) fibers), polycaprolactam fibers, poly(hexamethylene adipamide) fibers, acrylic fibers, acetate fibers, rayon fibers, nylon fibers, and combinations thereof.

[0121] In this regard, if other strands are used in the knitted structure, a strand 505 formed from a thermoplastic elastomer yarn as disclosed herein may form approximately any second course 505 to approximately any eleventh course 505 (for example, the strand may be positioned in any fourth to tenth course). Preferably, such a strand may form any fourth, fifth, or sixth course 505 in the knitted structure 500. Typically, the spacing may remain constant throughout the knitted structure 500. In other embodiments, the spacing of such strands 505 may be varied to change the recovery and / or stretch properties throughout the article (e.g., clothing). As a specific example, such a strand 515 may form any fourth course 505 of the article in one part of the article, but may form any sixth course along another part of the article.

[0122] In further embodiments, each strand 515 may include a strand formed from a thermoplastic elastomer as disclosed herein, paired with the corresponding strand 515 (for example, the strands are knitted or otherwise mixed). The strand pairs are then utilized to form courses 505 within the knitted structure 500.

[0123] In any configuration, the amount of strand 515 formed from thermoplastic elastomers as disclosed herein may be present in the knit structure in amounts such as about 0.1% or more by weight, for example, about 0.5% or more, for example, about 1% or more, for example, about 2% or more, for example, about 3% or more, for example, about 5% or more, for example, about 10% or more, for example, about 15% or more, for example, about 20% or more, for example, about 25% or more, for example, about 30% or more, for example, about 40% or more, for example, about 50% or more, for example, about 60% or more, for example, about 70% or more, for example, about 80% or more, for example, about 90% or more, for example, about 95% or more, for example, about 100% or more. Such strands may be present in amounts of approximately 100% or less by weight, for example, approximately 98% or less, for example, approximately 95% or less, for example, approximately 90% or less, for example, approximately 80% or less, for example, approximately 75% or less, for example, approximately 70% or less, for example, approximately 65% ​​or less, for example, approximately 60% or less, for example, approximately 55% or less, for example, approximately 50% or less, for example, approximately 45% or less, for example, approximately 40% or less, for example, approximately 35% or less, for example, approximately 30% or less, for example, approximately 25% or less, for example, approximately 20% or less, for example, approximately 15% or less, for example, approximately 10% or less, for example, approximately 5% or less.

[0124] Knitted structures can also be double knitted structures. Generally, such structures can be formed on a knitting machine having two needle beds. These machines may include, but are not limited to, V-bed flat knitting machines and double jersey circular knitting machines. A double knitted structure can provide a technical face knitted on one of the needle beds and a technical back knitted on the other needle bed of the knitting machine. When viewing the technical face and technical back of a double knitted structure, both sides may look like the technical face of a single knit jersey and may contain face loops or weft loops. In certain embodiments, a connecting yarn may be used to connect the technical face and technical back of a double knitted structure, with the connecting yarn passing back and forth between two different needle beds. A double knitted structure can be formed on a machine where the needles of one bed are directly opposite the needles of the other bed (known as interlock knitting). A double knitted structure can also be formed on a machine where the needles of one bed are in the space directly opposite the other bed (known as rib knitting).

[0125] In the double-knit structure described above, the technical face may form the outward-facing surface of the resulting article, and the technical back may form the inward-facing surface of the resulting article. The technical face of the structure may be formed from a first yarn. The first yarn may be any type of yarn commonly used for yarn, such as an inelastic or elastic yarn, for example, yarns disclosed herein. Examples of inelastic yarns include polyamide yarns, cotton yarns, and / or polyester yarns. The technical back of the structure may be formed from a second yarn and optionally from the first yarn. The second yarn may be an elastic yarn, such as yarns disclosed herein.

[0126] In such a configuration, the amount of the second elastic yarn may be present in the knit structure in amounts such as approximately 0.1% or more by weight, for example, approximately 0.5% or more, for example, approximately 1% or more, for example, approximately 2% or more, for example, approximately 3% or more, for example, approximately 5% or more, for example, approximately 10% or more, for example, approximately 15% or more, for example, approximately 20% or more, for example, approximately 25% or more, for example, approximately 30% or more, for example, approximately 40% or more, for example, approximately 50% or more, for example, approximately 60% or more, for example, approximately 70% or more, for example, approximately 80% or more, for example, approximately 90% or more, for example, approximately 95% or more, for example, approximately 100%. Such yarn may be present in amounts of approximately 100% or less by weight, for example, approximately 98% or less, for example, approximately 95% or less, for example, approximately 90% or less, for example, approximately 80% or less, for example, approximately 75% or less, for example, approximately 70% or less, for example, approximately 65% ​​or less, for example, approximately 60% or less, for example, approximately 55% or less, for example, approximately 50% or less, for example, approximately 45% or less, for example, approximately 40% or less, for example, approximately 35% or less, for example, approximately 30% or less, for example, approximately 25% or less, for example, approximately 20% or less, for example, approximately 15% or less, for example, approximately 10% or less, for example, approximately 5% or less.

[0127] The knitted structure can be incorporated into garments, whether following the structure of Figure 7 or any other structure as described herein. Garments are not necessarily limited by this disclosure. For example, a garment may be a tubular knitted fabric, which is a fabric knitted in a desired three-dimensional structure, as opposed to a two-dimensional fabric which is cut, sewn, and otherwise manipulated to produce a three-dimensional structure. However, it should be understood that yarns and fabrics can be equally well utilized in two-dimensional fabrics.

[0128] In this regard, clothing or garments include, but are not limited to, short-sleeved or long-sleeved shirts, tank tops, undershirts, jackets, coats, pants, trousers, shorts, socks, underwear, nylon / leggings, dresses, skirts, hats / headgear, outerwear, etc. Other items of clothing or garments include, but are not limited to, sleepwear, swimwear, compression garments, denim, sportswear, and other stretchy garments. Apart from clothing, other uses for these fabrics include, but are not limited to, interior decorating materials, curtains, toys, car covers, furniture, and equipment.

[0129] Test method Elongation at break and tenacity: Elongation at break and tenacity were measured at a temperature of approximately 23°C according to ASTM D2653-07 (2018). For the apparatus used to perform the test, option A under the clamp assembly was used. A tensile testing machine was used with a gauge length of approximately 2 inches. For this test, 10 specimens were tested and the average was recorded.

[0130] Denier and Fiber Shrinkage: Denier and fiber shrinkage were measured according to ASTM D2259-02 (2016). Denier was measured at a temperature of approximately 23°C. For these tests, 90 wraps were completed, carefully tying the untied ends without inducing any extra tension on the skein or cutting any excess yarn. To measure the denier, the skein was placed on a balance scale according to the standard method, and the weight was recorded, obtaining the denier value based on the skein length. In addition, fiber shrinkage was measured according to Section 6.6.1, Step 13, using dry heat exposure at a temperature of approximately 120°C. Specifically, the skein was suspended inside an oven and heated in the oven for 15 minutes. The amount of shrinkage was then measured by measuring the length of the skein. [Examples]

[0131] Example 1 Thermoplastic copolyether ester elastomer (flexural modulus -45 MPa; hardness -33 Shore D; Tm -193℃; density -1.1 g / cm³) 3The material was spun to form a multifilament yarn consisting of three filaments according to the schematic diagram shown in Figure 1. Specifically, a pellet of thermoplastic copolyether ester elastomer was fed into an extruder and heated. The extruder included a screw 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 was fed into a spinneret pack operating at approximately 260°C, which contained four spinnerets, each having three die holes. The melt was supplied using a melt pump operating at 5.5 rpm, delivering approximately 4.114 g / min to each of the four spinnerets. The spinneret plate contained 0.028 inch diameter die holes appropriately spaced to allow three separate filaments to be extruded to form a multifilament yarn. Upon exiting the spinneret, the filament was cooled using ambient quenching without additional quenching airflow. A ceramic guide (0.5 mm, 3-dimple low-friction guide) was used to guide the filament and act as a finishing applicator. The ceramic guide also allows the filaments to coalesce and at least partially bond to each other at a temperature lower than the melting temperature of the hard segment of the thermoplastic copolyether ester elastomer but higher than the glass transition temperature. The finishing applicator was positioned approximately 11.5 feet from the surface of the spinneret pack. For finishing application, a silicone oil finishing agent (pumped at 0.189 g / min) was applied to the filament in an amount of approximately 4.4 wt% based on the total weight of the yarn. The feed roll speed was approximately 1000 m / min, the winder speed was approximately 1000 m / min, and the stretch (or godet) roll between the winder and the feed roll was approximately 1100 m / min. When the winding speed is slower than the godet roll speed, the filaments and threads have the opportunity to relax, at least partially.

[0132] The spinning process yielded a 40-denier multifilament yarn. In addition, the yarn also exhibited the following characteristics: tenacity - 1.04 g / d; elongation at break - 393%; shrinkage - 7.9%. Figure 9 provides an optical micrograph of the multifilament yarn, highlighted within the circle. In particular, the micrograph shows that the three extruded filaments are not fused together but at least partially bonded to form the multifilament yarn. The yarn was then knitted at commercial speed on a Monarch 30-gauge 32-inch machine to produce a fabric free of yarn or fabric defects.

[0133] These and other modifications and variations of the Disclosure may be made by those skilled in the art without departing from the spirit and scope of the Disclosure. In addition, it should be understood that the various embodiments may be replaced both in whole and in part. Furthermore, those skilled in the art will fully understand that the foregoing description is merely illustrative and is not intended to limit the invention to such further described inventions in such appended claims.

Claims

1. A multifilament yarn comprising a first filament at least partially bonded to a second filament, wherein 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 measured according to ISO 178:2019 at a temperature of about 23°C, and further comprising a multifilament yarn having a linear density of about 1 to about 500 deniers per filament and exhibiting an elongation at break of about 300% or more as measured according to ASTM D2653-07 (2018) at a temperature of about 23°C.

2. The multifilament yarn according to claim 1, exhibiting shrinkage of about 50% or less as measured according to ASTM D2259-02 (2016) (Section 6.6.1 - Dry heat exposure).

3. The multifilament yarn according to claim 1 or 2, exhibiting a tenacity of about 0.7 grams or more per denier as measured according to ASTM D2653-07 (2018) at a temperature of about 23°C.

4. A multifilament yarn according to any one of claims 1 to 3, exhibiting at least about 75% recoverable elasticity as measured according to ASTM D6720-07 (2018).

5. The multifilament yarn according to any one of claims 1 to 4, wherein the thermoplastic elastomer exhibits one or more of the following: a Shore D hardness of about 60 or less as measured according to ISO 868:2003 (test time of 15 seconds) at a temperature of about 23°C; a melting temperature of about 100°C to about 230°C as measured according to ISO 11357-3:2018; or a tensile stress at fracture of about 45 MPa or less as measured according to ISO 527-1 / -2 (2012) at a temperature of about 23°C.

6. The multifilament yarn according to any one of claims 1 to 5, wherein the thermoplastic elastomer is a thermoplastic copolyether ester elastomer.

7. The multifilament yarn according to any one of claims 1 to 6, wherein the thermoplastic elastomer is a thermoplastic copolyester elastomer containing hard segments and soft segments, the hard segments constitute about 20% by weight or more to about 70% by weight of the thermoplastic copolyester elastomer, and the soft segments constitute about 30% by weight or more to about 80% by weight of the thermoplastic copolyester elastomer.

8. The multifilament yarn according to any one of claims 1 to 7, wherein the thermoplastic elastomer is a thermoplastic copolyester elastomer containing a hard segment and a soft segment, and the hard segment is derived from at least one aromatic dicarboxylic acid and / or a diester thereof and at least one diol containing 2 to 15 carbon atoms.

9. The multifilament yarn according to claim 8, wherein the aromatic dicarboxylic acid comprises terephthalic acid, isophthalic acid, or a combination thereof, and the diol comprises ethylene glycol, 1,4-butanediol, 1,3-propanediol, or a combination thereof.

10. The multifilament yarn according to any one of claims 1 to 9, wherein the thermoplastic elastomer is a thermoplastic copolyester elastomer containing a hard segment and a soft segment, and the soft segment is derived from at least one aromatic dicarboxylic acid and / or a diester thereof and at least one poly(alkylene oxide) glycol.

11. The multifilament yarn according to claim 10, wherein the aromatic dicarboxylic acid comprises terephthalic acid, isophthalic acid, or a combination thereof, and the poly(alkylene oxide) glycol comprises poly(tetramethylene oxide) glycol, poly(trimethylene oxide) glycol, poly(propylene oxide) glycol, poly(ethylene oxide) glycol, poly(hexamethylene oxide) glycol, or a combination thereof.

12. The multifilament yarn according to any one of claims 1 to 11, wherein the thermoplastic elastomer comprises a thermoplastic copolyether ester elastomer prepared from a monomer comprising (1) poly(tetramethylene oxide) glycol, (2) a dicarboxylic acid selected from isophthalic acid, terephthalic acid or a mixture thereof, and (3) a diol selected from 1,4-butanediol, 1,3-propanediol or a mixture thereof.

13. The multifilament yarn according to any one of claims 1 to 12, wherein the first filament and the second filament are coated with a finishing agent.

14. The multifilament yarn according to claim 13, wherein the finishing agent includes a finishing oil containing silicone oil.

15. The multifilament yarn according to claim 13, wherein the finishing agent coats at least about 50% of the surface area of ​​the first filament and the second filament.

16. The multifilament yarn according to any one of claims 1 to 15, further comprising a third filament at least partially bonded to the first filament, the second filament, or both.

17. The multifilament yarn according to claim 16, wherein the first filament, the second filament, and the third filament are at least partially bonded to each other.

18. A method for producing a multifilament yarn according to any one of claims 1 to 17, wherein the method is Extruding a molten material containing the thermoplastic elastomer composition through a spinneret; To pull the first filament and the second filament from the spinneret to the supply roller; Rapid cooling of the first filament and the second filament using air; Applying a finishing agent to the first filament and the second filament; Collecting the first filament and the second filament on the winding roller Methods that include...

19. Stretching the first filament and the second filament using a stretching roller. The method according to claim 18, further comprising:

20. The method according to claim 19, wherein the supply roller speed is faster than the extension roller speed and / or the extension roller speed is faster than the winding roller speed.

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