A liquid crystal polymer monofilament, and method for producing the same

Abstract

A monofilament, a multifilament, and method for producing the same are provided. The monofilament may include a single monofilament containing a liquid crystal polymer (LCP). The LCP may be formed from a reaction between aromatic hydroxycarboxylic acids, and at least one comonomer selected from aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aliphatic carboxylic acids, aromatic hydroxyamines, aromatic diamines, aromatic diols, and aliphatic diols. The monofilament has a high tensile strength and high abrasion resistance. The multifilament may contain an interlaced article containing a plurality of monofilaments braided or woven to form the interlaced article.

Description

PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATIONPCT PATENT APPLICATIONInventors: Michael Zimmerman Vikram Sharma William ScavuzzoAttorney No.: 59496-00004TitleA LIQUID CRYSTAL POLYMER MONOFILAMENT, AND METHOD FOR PRODUCING THE SAMECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims benefit to U.S. Provisional Application No. 63 / 695,974 filed on September 18, 2024. The entire contents of this application is incorporated herein by reference in its entirety.BACKGROUND

[0002] Polymers such as poly vinylidene fluoride (“PVDF”) are a major component in many commercial products. PVDF is chemically resistant to acids, bases, organic solvents, automotive fluids, oils, gas, lubricants, fully halogenated hydrocarbons, and alcohols. PVDF has a high melting point and can withstand elevated temperatures without deforming, and is non-hygroscopic, has low smoke and flame characteristics and can have very good abrasion resistance.

[0003] PVDF is used in electronics e.g. wire insulation and cable jacketing; sensors and actuators e.g. pyroelectric and laser beam profile sensors; filtration and batteries e.g. filters and battery separators; in seals, gaskets, and coatings e.g. tubing, piping, underground fuel containment, and offshore oil platforms; consumer products e.g. fishing lines; and many other applications.

[0004] On the other hand, per- and polyfluoroalkyl substances (“PF AS”) are attracting global attention. Of particular note are compounds referred to as “specific PF AS,” such as perfluorooctanoic acid (PFOA) and perfluorooctanesulfonic acid (PFOS). These specific PFAS are known to be highly persistent, bio-accumulative, and toxic to humans. Specific PFAS are already regulated in many countries, with their manufacture and use being prohibited. Fluorinated compounds used in products such as conventional fishing lines are also broadly classified as PFAS, raising concerns about potential future regulations. Therefore, there is a demand for alternative material that are sustainable materials free of fluorinated compounds while still satisfying physical property requirements36819143.2 1PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATIONSUMMARY

[0005] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0006] In one aspect, embodiments disclosed herein relate to a monofilament. The monofilament may include a single monofilament. The single monofilament may contain a liquid crystal polymer formed from a reaction selected from the group consisting of (i) a polycondensation reaction between aromatic hydroxycarboxylic acids; and (ii) a polycondensation reaction between an aromatic hydroxy carboxylic acid and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aliphatic carboxylic acids, aromatic hydroxyamines, aromatic diamines, aromatic diols, and aliphatic diols.

[0007] In another aspect, embodiments disclosed herein relate to a multifilament. The multifilament may contain a interlaced article containing a plurality of monofilaments braided or twisted to form the multifilament article. The plurality of monofilaments may contain a liquid crystal polymer formed from a reaction selected from the group consisting of (i) a polycondensation reaction between aromatic hydroxycarboxylic acids; (ii) a polycondensation reaction between an aromatic hydroxy carboxylic acid and and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aliphatic carboxylic acids, aromatic hydroxyamines, aromatic diamines, aromatic diols, and aliphatic diols.

[0008] In yet another aspect, embodiments disclosed herein relate to a method of producing a monofilament may contain: polymerizing aromatic hydroxycarboxylic acids, and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aromatic diols, and aliphatic diols to form a liquid crystal polymer; melting the liquid crystal polymer to form a molten liquid crystal polymer; extruding the molten liquid crystal polymer to form an extruded liquid crystal polymer; and drawing the extruded liquid crystal polymer to form the monofilament. The monofilament may have a diameter ranging from 10 to 800 pm. The monomers are selected from the group consisting of (i) one or more aromatic hydroxycarboxylic acids; and (ii) an aromatic hydroxycarboxylic acid and at least one comonomer selected from the group consisting of aromatic dicarboxylic36819143.2 2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION acids, aliphatic dicarboxylic acids, aromatic hydroxyamines, aromatic diamines, aromatic diols, and aliphatic diols.

[0009] In another aspect, embodiments disclosed herein relate to a method for producing a multifilament. The method for producing a multifilament may include interlacing the monofilament obtained from the method of producing a monofilament, to form the multifilament.

[0010] Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.BRIEF DESCRIPTION OF DRAWINGS

[0011] FIG. 1 shows a monofilament in accordance with one or more embodiments.

[0012] FIGs. 2A-2B are examples of Scanning Electron Microscope (“SEM”) images of a cross sectional view of a liquid crystal polymer monofilament in accordance with one or more embodiments.

[0013] FIGs. 3A-3B show examples of multifilaments in accordance with one or more embodiments.

[0014] FIG. 4 shows an example of a multifilament in accordance with one or more embodiments.

[0015] FIG. 5 is a schematic illustration of a braid angle of the multifilament in accordance with one or more embodiments.

[0016] FIG. 6 shows a block flow diagram of a method of producing a monofilament in accordance with one or more embodiments.

[0017] FIG. 7 shows a block flow diagram of a method of producing a multifilament in accordance with one or more embodiments.

[0018] FIGs. 8A-8B are digital microscope images of the LCP monofilament in accordance with one or more embodiments and a commercial LCP monofilament respectively.

[0019] FIG. 9 shows a digital microscope image of coated LCP monofilament in accordance with one or more embodiments and a commercial LCP monofilament respectively.

[0020] FIG. 10 shows a graph of Y oung’ s modulus of LCP monofilaments prepared by different process conditions in accordance with one or more embodiments.

[0021] FIG. 11 shows results of the tensile strain vs tensile stress of monofilaments in accordance with one or more embodiments.36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATIONDETAILED DESCRIPTION

[0022] The present disclosure generally relates to a monofilament, a multifilament (which is a interlaced structure), and method for producing the same. The monofilament contains a single monofilament containing a liquid crystal polymer (“LCP”). The multifilament contains a plurality of monofilaments interlaced to form an interlaced article, wherein the monofilaments contain a LCP.Liquid Crystal Polymer

[0023] As noted above, the present disclosure relates to a monofilament that includes a LCP. LCP contains mesogens which are molecules derived from aromatic compounds. Mesogens have some degree of directionality which is referred to as “anisotropy” and are structured as rigid rods. Because of the mesogens, LCPs may have a nematic phase, smectic phase, or cholesteric phase. In one or more embodiments, the LCP disclosed herein may have a nematic phase.

[0024] In one or more embodiments, the LCP may be an aromatic polyester formed from a reaction between aromatic hydroxycarboxylic acids, and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aromatic diols, and aliphatic diols. Examples of chemical structures of LCPs are shown in formulas (I)-(III) below.

[0025] In a non-limiting example, the reaction between aromatic hydroxycarboxylic acids may result in a product that includes a structure of formula (II). The reaction between aromatic hydroxycarboxylic acid and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aromatic diols, and aliphatic diols may result in a product that includes a structure of36819143.2 4PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION formula (I) and / or formula (III). As a non-limiting example, the reaction between an aromatic hydroxy carboxylic acid, an aromatic diol, and an aromatic dicarboxylic acid may result in a product that includes a structure of formula (I). In another non-limiting example, a reaction between an aromatic hydroxycarboxylic acid, an aliphatic diol, and an aromatic di carboxylic acid may result in a product that includes a structure of formula (III).

[0026] Specifically, in one or more embodiments, the LCP may contain repeating units formed from a condensation polymerization reaction between aromatic hydroxycarboxylic acid monomers, or a condensation polymerization reaction between an aromatic hydroxy carboxylic acid monomer and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aromatic diols, and aliphatic diols. For example, the polymer structure may involve functional groups called "Mers" which refers to a repeating unit, and are polymerized in a long chain by either addition or condensation polymerization into a long polymer chain. The LCP may have an end cap group at one or more ends.

[0027] Examples of aromatic hydroxy carboxylic acids may include, but are not limited to, 4-hydroxybenzoic acid, 3-hydroxybenzoic acid, 2-hydroxybenzoic acid, 6- hydroxy-2-naphthoic acid, and halogen-, alkyl-, or allyl-substituted derivatives of hydroxybenzoic acid.

[0028] Examples of aromatic dicarboxylic acids may include, but are not limited to, terephthalic acid, isophthalic acid, 3,3’-diphenyl dicarboxylic acid, 4,4’-diphenyl dicarboxylic acid, 1,4-naphthalene dicarboxylic acid, 1,5 -naphthalene dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, and alkyl- or halogen-substituted aromatic di carboxylic acids such as t-buty l terephthal i c acid, and chloroterephthalic acid.

[0029] Examples of aliphatic dicarboxylic acids may include, but are not limited to, cyclic aliphatic dicarboxylic acids such as trans-l,4-cyclohexane dicarboxylic acid, cis-l,4-cyclohexane dicarboxylic acid, 1,3-cyclohexane dicarboxylic acid, and substituted derivatives thereof.

[0030] Examples of aromatic diols may include, but are not limited to, hydroquinone, biphenol, 4,4 ’-dihydroxy diphenyl ether, 3,4’-dihydroxydiphenyl ether, bisphenol A, 3,4’-dihydroxydiphenylmethane, 3,3 ’-dihydroxydiphenylmethane, 4, d’- dihydroxy diphenylsulfone, 3,4’-dihydroxydiphenylsulfone, 4,4’-dihydroxy- diphenylsulfide, 3,4’-dihydroxdiphenylsulfide; 2,6’-naphthalenediol;36819143.2 5PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION1,6'dihydroxybenzophenone, 3,4’ -dihydroxy benzophenone, 3,3’- dihydroxy benzophenone, 4,4’ -dihydroxy diphenyldimethylsilane, and alkyl- and halogen-substituted derivatives thereof.

[0031] Examples of aliphatic diols may include, but are not limited to, cyclic, linear, and branched aliphatic dials such as trans- 1,4-hexanediol, cis-l,4-hexanediol, trans- 1,3-cyclohexanediol, cis-l,2-cyclohexanediol; ethylene glycol, 1,4-butanediol, 1,6- hexanediol, 1,8-octanediol, trans-l,4-cyclohexanedimethanol, cis-1,4- cyclohexanedimethanol, and substituted derivatives thereof.

[0032] In one or more embodiments, a molar ratio between hydroxycarboxylic acid monomers is in the range of 80:20 to 70:30. The molar ratio between hydroxycarboxylic acid monomers is in a range having a lower limit of any one of 80:20, 79:21, 78:22, 77:23, 76:24, and 75:25 and an upper limit of any one of 75:25, 74:26, 73:27, 72:28, 71:29, and 70:30, where any lower limit can be paired with any mathematically compatible upper limit. The molar ratio may be adjusted based on the desired temperature performance and desired viscosity of the LCP.

[0033] In one or more embodiments, a molar ratio between the aromatic hydroxycarboxylic acid monomer(s) and the at least one comonomer is in a range from 100:0 to 70:30. The molar ratio between an aromatic hydroxycarboxylic acid monomer and at least one comonomer is in a range having a lower limit of any one of 100:0, 95:5, 90: 10, 85: 15, 80:20, 79:21, 78:22, 77:23, 76:24, and 75:25 and an upper limit of any one of 85: 15, 83: 17, 80:20, 78:22, 75:25, 74:26, 73:27, 72:28, 71:29, and 70:30, where any lower limit can be paired with any mathematically compatible upper limit.

[0034] Alternatively, in one or more embodiments, the LCP may be an aromatic polyester amide formed from a reaction between an aromatic hydroxy carboxylic acid, and at least one comonomer selected from the group consisting of aromatic di carboxylic acid, and aliphatic dicarboxylic acids; at least one comonomer selected from the group consisting of aromatic hydroxyamines and aromatic diamines; and / or at least one optional comonomer selected from the group consisting of aromatic diols, and aliphatic diols,. Specifically, in one or more embodiments, the LCP may contain repeating units formed from the condensation polymerization reaction between a hydroxycarboxylic acid monomer and at least one comonomer selected from the group consisting of aromatic dicarboxylic acid, and aliphatic carboxylic acids, at least on comonomer selected from the group consisting of aromatic hydroxyamines, and36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION aromatic diamines, and at least one optional comonomer selected from the group consisting of aromatic diols and aliphatic diols.

[0035] Examples of aromatic hydroxyamines may include, but are not limited to, 4- aminophenol, 3 -aminophenol, and substituted derivatives thereof

[0036] Examples of aromatic diamines may include, but are not limited to, p- phenylenediamine, m-phenylenediamine, and substituted derivatives thereof.

[0037] The LCP may have a molecular weight ranging from 5,400 Daltons (“Da”) to 17,000 Da. In one or more embodiments, the molecular weight of LCP may have a lower limit of one of 5,400, 5,600, 5,800, 6,000, 6,500, 7,000, 7,500, 8,000, 9,000, 10,000, 11,000 and 12,000 Da, and an upper limit of one of 11,000, 12,000, 13,000, 14,000, 15,000, 15,500, 16,000, 16,200, 16,400, 16,600, 16,800, and 17,000 Da, where any lower limit may be paired with any upper limit.

[0038] The invention is categorized into monofilament and multifilament in the view of filament structures. Monofilaments may be used in many applications. Meanwhile, a multifilament is formed from a plurality of monofilaments interlaced together and may be used in many different applications.A Monofilament

[0039] In one or more embodiments, a monofilament contains a single monofilament. The single monofilament contains the LCP as described above.

[0040] FIG. 1 is a schematic drawing of a monofilament 10, in accordance with one or more embodiments. Alternatively, in one or more embodiments, the monofilament may be coated with various coatings, as will be explained in subsequent sections. As shown in FIG. l, the monofilament contains a single monofilament. While the monofilament is shown with a circular cross-section, any cross-sectional shape may be used.

[0041] As shown in FIG. 1, the monofilament 10 may have a diameter do, which may range from 20 to 800 micrometers (pm). In one or more embodiments, the diameter do of the monofilament may have a lower limit of one of 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, and 450 pm, and an upper limit of one of 60, 70, 80, 90, 100, 150, 200, 250, 300, 350,400, 450, 500, 550, 600, 650, 700, 720, 730, 740, 750, 760, 770, 780, 790, and 800 pm, where any lower limit may be paired with any upper limit. As a non-limiting example, a monofilament of one or more embodiments may have a diameter do in the range from 20 to 60 pm.36819143.2 7PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION

[0042] The monofilament may have a knot strength in a range of 500 to 2100 MegaPascals MPa which is enabled by the lower modulus, high elongation and abrasion resistant monofilament. In one or more embodiments, the knot strength of the monofilament may have a lower limit of one of 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, and 1200 MPa, and an upper limit of one of 600, 700, 750, 800, 850, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, and 2100 MPa, where any lower limit may be paired with any upper limit. As a nonlimiting example, the monofilament has a knot strength ranging from 700 MPa to 2000 MPa, such as from 1000 MPa to 2000 MPa.

[0043] The monofilament may have a knot elongation ranging from 4% to 30%. In one or more embodiments, the knot elongation of the monofilament may have a lower limit of one of 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, and 20%, and an upper limit of one of 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, and 30%, where any lower limit may be paired with any upper limit.

[0044] The knot strength and knot elongation are measured based on Japanese Industrial Standards (“JIS”) L 1013 by making a knot with the monofilament, except that the gauge length is 150 mm and the tensile rate is 150 mm / min (millimeters per minute).

[0045] The monofilament may have a tensile strength ranging from 700 MPa to 3,100 MPa. In one or more embodiments, the tensile strength of the monofilament may have a lower limit of one of 700, 720, 740, 760, 780, 800, 850, 900, 1,000, 1,100, 1,200, 1,300, and 1,400 MPa, and an upper limit of one of 1,300, 1,400, 1,500, 1,600, 1,700, 1,800, 1,850, 1,900, 1,920, 1,940, 1,960, 1,980, 2,000 2,200, 2,400, 2,600, 2,800, 3,000, and 3,100MPa, where any lower limit may be paired with any upper limit. As a non-limiting example, a monofilament of one or more embodiments may have a tensile strength ranging from 2200 MPa to 3000 MPa.

[0046] The monofilament may have a tensile elongation ranging from 5% to 30%. In one or more embodiments, the tensile elongation of the monofilament may have a lower limit of one of 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, and 20%, and an upper limit of one of 16, 18, 20, 22, 24, 25, 26, 27, 28, 29, and 30%, where any lower limit may be paired with any upper limit.

[0047] The tensile strength and tensile elongation are measured based on Japanese Industrial Standards (“JIS”) L 1013 without making a knot with the monofilament, except that the gauge length is 150 mm and the tensile rate is 150 mm / min. The36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION maximum stress is taken as the tensile strength and the elongation at break is taken as tensile elongation. The measurement results of the tensile strength and tensile elongation are each obtained by calculating the average value of 5 measurements (n=5).

[0048] The monofilament may have a Young’s modulus ranging from 1 GPa (GigaPascals) to 120 GPa. In one or more embodiments, the Young’s modulus of the monofilament may have a lower limit of one of 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and 60 GPa, and an upper limit of one of 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99, 100, 100, 110, and 120 GPa, where any lower limit may be paired with any upper limit. In the present disclosure, the Young’s modulus refers to a slope of stress-strain curve between 90 MPa and 100 MPa. As a non-limiting example, a monofilament of one or more embodiments may have a Young’s modulus ranging from 50 GPa to 100 GPa.

[0049] The monofilament may have wet abrasion cycle in a range of 200 times to 2100 times. In one or more embodiments, the wet abrasion cycle of the monofilament may have a lower limit of one of 200, 250, 300, 400, 500, 600, 700, 800, 900, and 1000 times, and an upper limit of one of 300, 400, 500, 600, 800, 900, 1000, 1100, 1300, 1500, 1700, 1900, 2000, and 2100 times, where any lower limit may be paired with any upper limit. As a non-limiting example, a monofilament in accordance with one or more embodiments may have a wet abrasion cycle of at least 500 times, such as in a range from 500 to 2000 times.

[0050] In the present disclosure, the “wet abrasion” of the monofilament refers to a number of cycles that the monofilament is rubbed until the monofilament breaks. Specifically, a wet filament is moved back and forth repeatedly in the direction of the monofilament axis while contacting the sandpaper #1000 (JIS R6001) spread on a drum, in the circumferential direction of the drum. The drum has a diameter of 190 mm (millimeters). The reciprocating cycle of the monofilament is 26 times / min (times / minute), and the reciprocating width is 55 mm. The weight per filament cross- sectional area loaded on the monofilament is 10.5 kg / mm2(kilograms per millimeter squared). A constant flow of water (10 mL / min milliliters / minute) is pumped continuously to the monofilament to keep the monofilament wet throughout the wet abrasion measurement.

[0051] In one or more embodiments, the monofilament may have dry abrasion cycle of 200 times or more, such as 500 times or more, 800 time or more, or 1000 times or36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION more. In the present disclosure, the “dry abrasion” of the monofilament refers to a number of cycles that the monofilament is rubbed until the monofilament breaks. The dry abrasion is measured in a similar method to that of the wet abrasion described above, except that there is no water flow during the measurement.

[0052] The monofilament may be inert to most liquids and may absorb 0.04 wt% or less based on the total weight of the monofilament, such as 0.03 wt% or less, 0.02 wt% or less, or 0.01 wt% or less, of water.

[0053] The monofilament may have a friction coefficient ranging from 0.10 to 3.86. In one or more embodiments, the friction coefficient of the monofilament may have a lower limit of one ofO.l, 0.25, 0.50, 0.75, 0.90, 0.95, 1.00, 1.05, 1.10, 1.20, 1.40, 1.60, 1.80, 2.00, 2.20, 2.40, 2.60, and 2.80, and an upper limit of one of 2.40, 2.60, 2.80, 3.00, 3.20, 3.40, 3.60, 3.65, 3.70, 3.75, 3.80, and 3.86, where any lower limit may be paired with any upper limit.

[0054] The friction coefficient of the monofilament is evaluated based on American Society for Testing and Materials (“ASTM”) D1894-11, “Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film” and “Sheeting 1.”

[0055] Conventional LCPs typically suffer from poor abrasion resistance due to a “skin layer” that forms on the surface of the polymer. Upon abrasion the skin layer may break up into tiny fibrils, which deteriorates the filament. Some have tried to minimize the skin layer of the LCP to prevent such fibrillation. The present disclosure shows that increasing the skin layer thickness is critical to achieving desired properties for the monofilament necessary for interlacing and other applications. The monofilament may have a skin layer thickness of 50 nm (nanometers) or more, such as 100 nm or more, 150 nm or more, 200 nm or more, 250 nm or more, 300nm or more, 350 nm or more, 400 nm or more, 450 nm or more, or 500 nm or more. As a non-limiting example, the monofilament of one or more embodiments includes a skin layer that has a thickness of 500 nm or less.

[0056] The skin layer of the monofilament is measured by cross-sectioning the monofilament with focused ion beam (“FIB”) and imaging the skin layer using a scanning electron microscope (“SEM”). FIGs. 2A-2B are examples of SEM images of the cross section of the LCP monofilament. Specifically, FIG. 2B is an enlarged SEM image of the SEM image of FIG. 2A to show the skin layer of the LCP monofilament. As shown in FIG. 2B, 12 data points (Pal - Pa6 and Pa R1 - Pa R6) are obtained to measure the thickness in nanometers (“nm”) of the skin layer. The36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION thickness of the skin layer between each data point is measured, as shown in Table 1 below. Thus, SEM can be used to measure the thickness of any skin layer on an LCP monofilament.

[0057] [Table 1]

[0058] Thickness of the skin layer between data points Pal - Pa6 and Pa R1 - Pa R6.

[0059] The skin layer may have a Young’s modulus of 5.0 GPa or less, such as 4.0 GPa or less, 3.0 GPa or less, 2.0 GPa or less, or 1.0 GPa or less, in order to enhance the knot strength of the . In a non-limiting example, the monofilament of one or more embodiments includes a skin layer may that has a Young’s modulus of 1.0 GPa or less. The Young’s modulus of the skin layer may be measured by a nanoindentation measurement method. The nanoindentation measurement method is a depth-sensing technique used to characterize mechanical properties, such as hardness and elastic modulus at the nanoscale. The procedure utilizes a precision instrument equipped with a diamond indenter (e.g., Berkovich or spherical) of known geometry, along with high-resolution sensors for load and displacement, which is often operated within a vibration-isolated and temperature-controlled environment.

[0060] The measurement process for nanoindentation may include an approach phase where the indenter contacts the fiber surface, followed by a loading phase in which a controlled force is applied to induce penetration. An optional hold segment at peak load may be used to assess time-dependent deformation or correct for thermal drift. During unloading, the elastic recovery of the material is recorded, generating a loaddisplacement curve. Mechanical properties are then extracted from this curve. For example, hardness can be calculated as the peak load divided by the projected contact area, while the reduced elastic modulus (Er) is denved from the slope of the unloading curve as shown in Equation (1), below.36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION

[0061] In Equation (1), S is the stiffness that relates to the slope of the unloading curve; and A is the projected contact area.

[0062] The Y oung’s modulus of the skin layer is then determined by correcting for the indenter’s elastic properties using established contact mechanics equations, such as Equation (2), below.1 1 - v21 - v2Er=E+Et

[0063] In Equation (2), v refers to Poisson’s ratio of the sample; E is the Young’s modulus of the skin layer; Vi refers to Poisson’s ratio of the indenter; and Ei is the elastic modulus of the indenter, which is typically a diamond material.

[0064] Advanced modes such as a Continuous Stiffness Measurement (CSM) and / or spatial mapping may be employed for depth-dependent or heterogeneous surface analysis.A Multifilament

[0065] Braiding and weaving are both methods of making multifilament articles by interlacing monofilaments in an over / under pattern. Woven articles comprise interlacing monofilaments to create myriad articles with varying textures, appearances, and functionalities. Woven articles are created by interlacing two sets of monofilaments at generally right angles: the warp (lengthwise) and the weft (crosswise). This orthogonal structure gives woven articles stability, thus making them suitable for numerous applications. While the interlacements in weaving methods are generally based on 90 degree angles, braiding uses "oblique" angles i.e. not 90 degrees. Due to the tight interlacing of monofilaments, woven and braided articles generally exhibit high tensile strength and durability, resisting wear and tear effectively. Further, monofilaments with different dimensions and physical properties may be used in such interlacing methods to provide the desired properties. Different diameter monofilaments can be utilized as the warp and weft for example.

[0066] In one or more embodiments, a multifilament is a braided article containing a plurality of monofilaments braided to form the braided article. The plurality of36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION monofilaments constituting the braided article may be the monofilament as discussed above, but are not particularly limited, as long as the desired physical properties of the braided article are achieved. For example, the monofilaments of the braided article may have physical properties (e.g. tensile strength, tensile elongation, knot strength, knot elongation, Young's modulus, wet abrasion cycle, and friction coefficient) that are equivalent to the physical properties when braided as described below. In the present disclosure, the term "braided article” includes braid, twist, twist spin, or otherwise interleave components that form a singular obj ect. By combining a pl urali ty of filaments, the best features of each respective material may improve the overall performance of the multifilament.

[0067] FIGs. 3A-3B each show a multifilament, in accordance with one or more embodiments. In FIG. 3A, the multifilament 300A includes a monofilament 310 as a main monofilament and a plurality of supporting monofilaments 320a-f that are twisted along the longitudinal direction of the multifilament 300A. By combining a plurality of filaments, the best features of a plurality of materials may improve the overall performance of the multifilament 300 A.

[0068] In one or more embodiments, the multifilament 300 A includes a plurality of identical supporting filaments (i.e., 320a-f are the same material, diameters d320a-f are the same), a plurality of unique support filaments (i.e., diameters d320a-f are different and / or composition of 320a-f are different), or any combination thereof (e.g., multiple instances of one or more different supporting filaments).

[0069] While a circular cross-sectional shape of diameter dsio and d320a-f are shown, any cross-sectional shape, diameter, and / or dimensional measure may be used for the monofilaments 310 and 320a-f. Furthermore, while the monofilament 310 and monofilament 320a-f are shown in roughly equal size (drawings are not to scale), any relative ratio of the filament diameter (or appropriate dimension) may be used. Furthermore, while FIG. 3A shows six unique supporting monofilaments 320a-f as an example, any number greater than one may be used.

[0070] In one or more embodiments, the plurality of supporting monofilaments 320a-f may be radially distributed around the main monofilament 310. For example, the plurality of supporting filaments 320a-f may completely surround the main monofilament 310 in a core-sheath geometry along the longitudinal direction of the monofilament. The plurality of supporting monofilaments 320a-f may be distributed in a symmetrical or asymmetrical arrangement about the main monofilament 310. The36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION multifilament 300A may be characterized by major and minor axis diameters (e.g., dsA-i and d? \-2. respectively) or an effective diameter of the twisted filaments.

[0071] Alternatively, the multifilament may have no mam monofilament, and have multiple monofilaments braided together to form a multifilament. FIG. 3B shows a multifilament 300B in accordance with one or more embodiments. As shown in FIG. 3B, the multifilament 300B has no main monofilament and includes monofilaments 320a-f twisted together to form a multifilament 300B. The multifilament 300B may be characterized by major and minor axis diameters (e.g., d3B-i and d3B-2, respectively) or an effective diameter of the twisted filaments.

[0072] While a circular cross-sectional shape of diameter d320a-f are shown, any cross- sectional shape, diameter, and / or dimensional measure may be used for the monofilaments 320a-f. Furthermore, while the monofilaments 320a-f are shown in roughly equal size (drawings are not to scale), any relative ratio of the filament diameter (or appropriate dimension) may be used. Furthermore, while FIG. 3B shows six unique monofilaments 320a-f as an example, any number greater than one may be used.

[0073] Alternatively, in one or more embodiments, the multifilament may be in a braided structure formed from a plurality of monofilaments. The multifilament is formed by braiding multiple monofilaments or multifilament bundles, such as 6, 8, 12, 16, 20, 24, 28, 32, 36, 40, 44 and 48 ends. The multifilament may have one type of monofilament or multitude of different monofilaments. The multifilament structure may be round, flat, or a hybrid of a round and flat structure.

[0074] FIG. 4 shows an example of a multifilament, containing a braided multifilament structure formed from six monofilaments in accordance with one or more embodiments. In FIG. 4, the multifilament 400 includes six monofilaments 410, 420, 430, 440, 450, and 460 that are braided together along the longitudinal direction of the multifilament 400. By combining a plurality of filaments, the best features of a plurality of materials may improve the overall performance of the multifilament 400.

[0075] While FIG. 4 shows six unique monofilaments 410, 420, 430, 440, 450, and 460, any number greater than one may be used. The braided multifilament article in multifilament 400 may be interwoven to form any braid structure (e.g., diamond, regular, and hercules) or ordered in any combination (e.g., braid sequence / complexity).36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION

[0076] The braided structure of the multifilament can be customized by varying the number of strands, the braiding angle, and the materials used.

[0077] The braided article may have a carrier count ranging from 4 to 54. In one or more embodiments, the earner count of the braided article may have a lower limit of one of 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 25, 30, 35, and 40 and an upper limit of one of 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 22, 24, 25, 28, 30, 32, 35, 38, 40, 42, 45, 48, 50, 52, and 54, where any lower limit may be paired with any upper limit. The “carrier count” of the present disclosure is a commonly known phrase by a person of ordinary skill in the art, and refers to a number of strands braided to form the multifilament.

[0078] The interlaced multifilament article may have picks per inch (“PPI”) ranging from 2 to 12. In one or more embodiments, the PPI of the braided article may have a lower limit of one of 2, 3, 4, 5, 6, 7, 8, and 9, and an upper limit of one of 5, 6, 7, 8, 9, 10, 11, and 12, where any lower limit may be paired with any upper limit. The “PPI” of the present disclosure is a commonly known phrase by a person of ordinary' skill in the art, and refers to a number of times the carriers cross each other in a weaving process to form the multifilament.

[0079] In an aspect, the woven multifilament article may have picks per inch (“PPI”) ranging from about 30 to about 700 PPI. In one or more embodiments, the PPI of the braided article may have a lower limit of one of 30, 40, 50, 60, 70, 80, and 90, and an upper limit of one of 100, 200, 300, 400, 500, 600, 650, 700, where any lower limit may be paired with any upper limit. The “PPI” of the present disclosure is a commonly known phrase by a person of ordinary' skill in the art, and refers to a number of times the carriers cross each other in a weaving process to form the multifilament.

[0080] The braided multifilament article may have a braiding angle ranging from 10 degrees to 45 degrees. In one or more embodiments, the braiding angle of the braided multifilament article may have a lower limit of one of 10, 11, 12, 13, 14,15, 20, 25, 30, and 40 degrees, and an upper limit of one of 20, 25, 30, 35, 40, 41, 42, 43, 44, and 45 degrees, where any lower limit may be paired with any upper limit. FIG. 5 is a schematic illustration of the braid angle in accordance with one or more embodiments. As shown in FIG. 5, the braid angle 0 in the present disclosure is the angle between the braid axis 502 and bias direction 504 made by crossing filaments 506 in the braid 500.36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION

[0081] The braided multifilament article may have a fineness ranging from 60 to 2000 dtex (deci -tex, or grams per 10000 meters of line). In one or more embodiments, the fineness of the braided article may have a lower limit of one of 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 800, 900, 1,000, 1,100, and 1,200 dtex, and an upper limit of one of 900, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500, 1,600,1.650. 1.700. 1.750. 1.800. 1.850. 1.900. 1.950. 1.960, 1,970, 1,980, 1,990, and 2,000 dtex, where any lower limit may be paired with any upper limit. In the present disclosure, the “fineness” refers to a calculated weight of the 50 m of a braided multifilament article multiplied by 200.

[0082] The LCP multifilament of one or more embodiments of the present disclosure may have the following properties.

[0083] The multifilament may have a knot strength ranging from 500 MPa to 2,100 MPa. In one or more embodiments, the knot strength of the multifilament may have a lower limit of one of 500, 600, 700, 800, 900, 1,000, 1,020, 1,040, 1,060, 1,080, 1,100, 1,150, 1,200, 1,250, 1,300, 1,400, 1,500, and 1,600, MPa, and an upper limit of one of 1,300, 1,400, 1,500, 1,600, 1,700, 1,750, 1,800, 1,850, 1,900, 1,920, 1,940,1.960, 1,980, 2,000, and 2,100 MPa, where any lower limit may be paired with any upper limit. As a non-limiting example, the multifilament may have a knot strength ranging from 800 MPa to 2000 MPa, such as from 1000 MPa to 2000 MPa.

[0084] The multifilament may have a knot elongation ranging from 1 to 6 %). In one or more embodiments, the knot elongation of the multifilament may have a lower limit of one of 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0%, and an upper limit of one of 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, and 6.0%, where any lower limit may be paired with any upper limit.

[0085] In one or more embodiments, the knot strength and knot elongation of the multifilament are measured as discussed above. A cross-sectional area of the braided article (for the purposes of determining knot strength and knot elongation, or other properties described below) is calculated by multiplying the cross-sectional area of the monofilaments by the number of monofilaments constituting the braided article.

[0086] The multifilament may have a tensile strength ranging from 1 ,400 MPa to 3, 100MPa. In one or more embodiments, the tensile strength of the multifilament may have a lower limit of one of 1,400, 1,420, 1,440, 1,460, 1,480, 1,500, 1,520, 1540, 1,560, 1,580, 1,600, 1,650, 1,700, 1,750, 1,800, 1,850, 1,900, 1,950, 2,000, 2,100, 2,200,36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION2.300, and 2,400 MPa, and an upper limit of one of 2,000, 2,100, 2,200, 2,300, 2,400, 2,450, 2,500, 2,550, 2,600, 2,650, 2,700, 2,750, 2,800, 2,820, 2,840, 2,860, 2,880, 2,900, 2,920, 2,940, 2,960, 2,980, 3,000, and 3100 MPa, where any lower limit may be paired with any upper limit. As a non-limiting example, the multifilament of one or more embodiments may have a tensile strength ranging from 2200 MPa to 3000 MPa.

[0087] The multifilament may have a tensile elongation ranging from 1.8% to 6.0%. In one or more embodiments, the tensile elongation of the multifilament may have a lower limit of one of 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, and 2.7%, and an upper limit of one of 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3., 3.4, 3.5, 4.0, 4.5, 5.0, 5.5, and 6.0%, where any lower limit may be paired with any upper limit. The tensile strength and tensile elongation of the multifilament are measured as discussed above.

[0088] The multifilament may have a Young’s modulus of greater than 30 GPa, such as greater than 40 GPa, greater than 50 GPa, or greater than 60 GPa. In the present disclosure, the Young’s modulus refers to a slope of stress-strain curve between 900 MPa and 1000 MPa. Young’s modulus relates to bending stiffness of the fiber and therefore, modifying to the above range may improve the ability of the monofilament to be interlaced without damage to the monofilament. As a non-limiting example, the multifilament of one or more embodiments may have a Young’s modulus of at least 50 GPa.

[0089] The multifilament may have wet abrasion cycle in a range of 400 times to 2,000 times. In one or more embodiments, the wet abrasion cycle of the multifilament may have a lower limit of one of 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1,000, 1,100, 1,200, and 1,300 times, and an upper limit of one of 1,100, 1,200,1.300, 1,400, 1,450, 1,500, 1,550, 1,600, 1,650, 1,700, 1,750, 1,800, 1,850, 1,900, 1,950 and 2,000 times, where any lower limit may be paired with any upper limit The wet abrasion test is as described above. As a non-limiting example, a multifilament in accordance with one or more embodiments may have a wet abrasion cycle of at least 500 times, such as in a range from 500 times to 2,000 times.

[0090] The multifilament may be inert to most liquids and may absorb 0.04 wt% or less based on the total weight of the multifilament, such as 0.03 wt% or less, 0.02 wt% or less, or 0.01 wt% or less, of water.36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION

[0091] The multifilament may have a friction coefficient ranging from 0. 1 to 3.86. In one or more embodiments, the friction coefficient of the multifilament may have a lower limit of any one of 0.10, 0.12, 0.14, 0.16, 0.18. 0.20, 0.22, 0.24, 0.30, 0.50, 0.70, 0.90, 1.00, 1.50, and 2.00, and an upper limit of any one of 1.50, 2.00, 2.50, 3.00, 3.50, 3.70, 3.72, 3.74, 3.76, 3.78, 3.80, 3.82, 3.84, and 3.86, where any lower limit may be paired with any upper limit. In one or more embodiments, the friction coefficient is measured as discussed above.A Method for Producing a Monofdament

[0092] In one aspect, embodiments disclosed herein relate to a method of producing a monofilament. The method may include polymerizing aromatic hydroxycarboxylic acids, and at least one comonomer selected from the group consisting of aromatic di carboxylic acids, aliphatic dicarboxylic acids, aromatic diols, and aliphatic diols to form a LCP. Alternatively, in one or more embodiments, the method may include polymerizing aromatic hydroxy carboxylic acids, and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aromatic diols, and aliphatic diols, aliphatic carboxylic acids, aromatic hydroxyamines, and aromatic diamines to form a LCP.

[0093] In one or more embodiments, the method may further include melting the LCP to form a molten LCP; extruding the molten LCP to form an extruded LCP; and drawing the extruded LCP to form the monofilament.

[0094] In one or more embodiments, the polymerizing may include a condensation polymerization. The “condensation polymerization” of the present disclosure refers to a reaction in which monomers of hydroxycarboxylic acids, and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aromatic diols, and aliphatic diols react to form a LCP while releasing by-products. The condensation polymerization may be melt polymerization, solution polymerization, or solid-phase polymerization.

[0095] In one or more embodiments, the polymerization may be produced in an inert gas atmosphere under anhydrous conditions. Examples of inert gas may include, but are not limited to, nitrogen and argon, among others.

[0096] Specifically, in one or more embodiments, the melt polymerization may be, for example, a melt acidolysis method. First, the hydroxycarboxylic acids and aromatic di carboxylic acids may be mixed and heated at 300°C for 2 hours in a reaction vessel including a nitrogen introduction tube and a distillation head or cooler, and then36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION stirred. Next, by-products, such as acetic acid, are collected and removed through the distillation head or cooler. After the quantity of collected by-products becomes constant, and the polymerization is almost completed, the melted lump may be heated under a vacuum (e.g. 10 mmHg or lower) and the remaining by-products are removed, thereby completing the polymerization.

[0097] Once the polymer is formed, it may then be extruded. In one or more embodiments, the extruding may be performed with an extruder. The extruder may be any type of extruder known to those skilled in the art to extrude the polymer. For example, a die of the extruder may have a diameter in a range of from about 100 pm to 500 pm. The temperature of extrusion may be in range of from about 280 °C to 360 °C. In one or more embodiments, the extrusion temperature may have a lower limit of one of 280, 282, 284, 286, 288, 290, 295, 300, 305, 310, 320, 330, and 340 °C, and an upper limit of one of 300, 310, 320, 330, 335, 340, 345, 350, 352, 354, 356, 358, and 360 °C, where any lower limit may be paired with any upper limit.

[0098] The extrusion may be performed with a speed in a range of from about 50 meters / minute (“m / min”) to 750 m / min. In one or more embodiments, the extrusion speed may have a lower limit of one of 50, 52, 54, 56, 58, 60, 65, 70, 75, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, and 500 m / min, and an upper limit of one of 300, 350, 400, 450, 500, 550, 600, 650, 700, 710, 720, 725, 730, 735, 740, 742, 744, 746, 748, and 750 m / min, where any lower limit may be paired with any upper limit.

[0099] After the extrusion, the extruded polymer may be quenched to a temperature ranging from -192 °C to 300 °C. In one or more embodiments, the quench temperature may have a lower limit of one of -192, -188, -186, -182, -178, -174, -170, -150, -130, -110, -90, -70, -50, -30, -10, 0, 10, 30, 50, and 70°C, and an upper limit of one of 20, 40, 60, 80, 100, 120, 140, 160, 180, 200, 220, 240, 260, 276, 280, 284, 288, 292, 296, and 300°C, where any lower limit may be paired with any upper limit. The quench temperature may be in the above temperature range to adjust the mechanical properties and abrasion resistance of the monofilament.

[0100] Then, the extruded polymer may be drawn to form the monofilament. In one or more embodiments, the drawing of the extruded LCP may be performed with godet rolls, to obtain a monofilament. For example, after the extruded polymer exits the die, the extruded polymer may be w rapped around one or more godet rolls, through a noncontact diameter measurement, and then onto a winding mechanism. A closed loop winder speed control may be synced with the godet rolls speed and the extruder output36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION to determine how the filament is drawn down in diameter, to determine the draw ratio (“DR”), and measure the final diameter of the monofilament. In the present disclosure, DR is defined as the ratio of the cross-sectional area of the die opening to the cross-sectional area of the final monofilament.

[0101] In one or more embodiments, DR may range from about 9 to 156, based on the diameter and desired mechanical properties of the of the monofilament. For example, DR may have a lower limit of one of 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 80, and 90, and an upper limit of one of 70, 80, 90, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 151, 152, 153, 154, 155, and 156, where any lower limit may be paired with any upper limit. Furthermore, the drawing speed may be in a range of from about 50 meters / minute (“m / min”) to 750 m / min. In one or more embodiments, the drawings speed may have a lower limit of one of 50, 52, 54, 56, 58, 60, 65, 70, 75, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, and 500 m / min, and an upper limit of one of 300, 350, 400, 450, 500, 550, 600, 650, 700, 710, 720, 725, 730, 735, 740, 742, 744, 746, 748, and 750 m / min, where any lower limit may be paired with any upper limit.

[0102] The monofilament obtained from the above described method may have a diameter ranging from 20 pm to 800 pm. In one or more embodiments, the diameter do of the monofilament may have a lower limit of one of 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, and 450 pm, and an upper limit of one of 400, 450, 500, 550, 600, 650, 700, 720, 730, 740, 750, 760, 770, 780, 790, and 800 pm, where any lower limit may be paired with any upper limit.

[0103] FIG. 6 is a flow chart of a method of producing a monofilament, in accordance with one or more embodiments. At 600, a LCP is formed by polymerizing hydroxycarboxylic acids, and at least one comonomer selected from the group consisting of aromatic dicarboxy lie acids, aliphatic dicarboxylic acids, aromatic diols, and aliphatic diols. At 620, the obtained LCP is melted to form a molten LCP. At 640, the molten LCP is extruded to form an extruded LCP. At 660, the extruded LCP is drawn to form the monofilament.

[0104] In one or more embodiments, the method may further include adding additives to the LCP to enhance the strength and / or abrasion resistance of the monofilament. For example, additives may be added to the LCP during the melting, during the extruding, and / or after the extruding such that the additives are attached to the surface of the LCP. Examples of additives may include, but are not limited to glycidyl epoxy,36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION novolac epoxy, cycloaliphatic epoxy, aromatic epoxy, silane and combinations thereof. The additives may be added in an amount in a range from about 3 to 7 wt% (weight percent) based on the amount of the LCP. For example, in one or more embodiments, the amount of additives may range from a lower limit of one of 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, 4.8, 5, 5.2, and 5.4 wt% of an upper limit of one of 4.6, 4.8, 5, 5.2, 5.4, 5.6, 5.8, 6, 6.2, 6.4, 6.6, 6.8, and 7.0 wt%, based on the amount of the LCP, where any lower limit may be paired with any mathematically compatible upper limit.

[0105] In one or more embodiments, the method may further include coating the monofilament with coatings to enhance abrasion resistance of the monofilament. The coating may contain a lubricant to further enhance abrasion resistance. A non-limiting example of a lubricant is silicone. For example, the coatings may be applied to the monofilament by pulling the monofilament through a bath filled with coatings, and then pulling the monofilament through a die with an opening having a diameter greater than the diameter of the monofilament, such that the coatings are coated with appropriate thickness on the surface of the monofilament.

[0106] In another aspect, the coatings may be applied to the monofilament by pulling the monofilament over a roller or it may be guided over and under a roller or multitude of rollers. The roller in above examples is turning in a bath filled with coatings, a technique that maybe termed as roller coating, reverse roll coating and or gravure roll coating. The coated monofilament may go through a die with an opening having a diameter greater than the diameter of the monofilament, such that the coatings are coated with appropriate thickness on the surface of the monofilament or through a set of sponges and or mechanical scraping of excess coating, before the coated monofilament traverses into the heating chamber.

[0107] In another aspect the coating maybe applied on the monofilament through cross head extrusion where in the monofilament one or multiple monofilaments go through a cross-head extruder and die block, then the monofilament / s, are pulled through a die block which has multiple opening having a diameter greater than the diameter of the monofilament, such that the coatings are coated with appropriate thickness on the surface of the monofilament.

[0108] In another aspect the coating maybe applied on the monofilament through core and sheath structure during the extrusion of monofilament where in the monofilament one or multiple monofilaments as being extruded through a spinneret, has a sheath36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION layer of the coating to create a composite structure having monofilament in core and abrasion coating in the sheath.

[0109] In another aspect of the invention, the coating may be used as a protective layer. The protective layer may be used temporarily for the purpose of preventing fibrillation from an interlacing method. The protective layer may then be removed or allowed to remain as desired. A monofilament coated with a protective layer may be used in an interlacing method to produce an interlaced article e.g. woven multifilament article. The woven multifilament article may then be immersed in an appropriate solvent for a sufficient time to remove all of or a portion thereof the protective article. In a related aspect, multiple protective layers may be applied to a monofilament with the exterior layer applied onto an inner layer which had been coated onto the surface of the monofilament. In this related aspect, the outer layer may be removed leaving the inner layer adhered to the monofilament. Solvents used to remove such a protective layer can be chosen based on the coating. For example, water may be useful to remove a PVA layer which is water soluble. A nonaqueous solvent may be alternatively chosen when the coating is not water soluble or when the solvent provides the desired effect on the protective layer.

[0110] Examples of coatings may include, but are not limited to, siloxane, polydimethylsiloxane (PDMS), polyvinyl alcohol (PVA), silicon carbide filled epoxy, and urethane. The coatings may be added in an amount in a range from about 0.5 wt% to 5 wt% based on the weight% of the monofilament. For example, in one or more embodiments, the amount of coatings may range from a lower limit of one of 0.5, 0.7, 0.9, 1, 1.2, 1.4, 1.6, 1.8, 2.0, 2.2, 2.4, 2.6, 2.8 and 3 wt% of an upper limit of one of 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.5, 4.6, 4.8, and 5 wt%, based on the amount of the monofilament, where any lower limit may be paired with any mathematically compatible upper limit.A Method for Producing a Multifilament

[0111] In one aspect, embodiments disclosed herein relate to a method of producing a multifilament. The method may include braiding the monofilament obtained from the method described above. Alternatively, the monofilaments used to make the braided articles may differ from the monofilament described above.

[0112] FIG. 7 is a flow chart of a method of producing a multifilament, in accordance with one or more embodiments. At 700, a LCP is formed by polymerizing aromatic hydroxycarboxylic acids, and at least one comonomer selected from the group36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aromatic diols, and aliphatic diols. At 720, the obtained LCP is melted to form a molten LCP. At 740, the molten LCP is extruded to form an extruded LCP. At 760, the extruded LCP is drawn to form the monofilament. At 780, a plurality of monofilaments are interlaced to form the multifilament.

[0113] Specifically, in one or more embodiments, a plurality of monofilaments is twisted or braided together along the longitudinal direction of the multifilament. Any relative ratio of the filament diameter (or appropriate dimension) may be used. For example, a smaller monofilament may provide sufficient tensile strength to the multifilament while a larger monofilament may be provided to support the monofilament to provide the desired bending resistance to the monofilament. Alternatively, in one or more embodiments, a main monofilament and a plurality of supporting monofilaments may be braided along the longitudinal direction of the multifilament. The multifilament may include a plurality of identical supporting filaments, a plurality of unique support filaments, or any combination thereof.

[0114] Interlacing of the monofilaments to form a braided article in a multifilament may be executed in any direction (e g., clockwise or counterclockwise twisting / spinning / twist spinning) or ordered in any combination (e.g., braid sequence / complexity). Furthermore, the braid can be made tailored to specification by additionally selecting the ppi and interlacing or braid angle. The details of the interlaced multifilament article are discussed in the previous section. In a aspect, interlaced or braided articles may be made with monofilaments and or with multifilament or a combination thereof. A braided interlaced or structure can made from multiple monofilaments or multifilament bundles). The braid can comprise 6, 8, 12, 16, 20, 24, 48 ends

[0115] In other aspects: the braided structure can be made in a combination of Monofilaments and Multifilaments; the braided structure can be made in a combination of Monofilaments and or Multifilament in the core with either monofilaments and or multifilament or a combination thereof with a technique called “over braiding”; the braided structure can be made in a combination of Monofilaments and or Multifilaments using a technique of flat braiding which may be generated on a circular braid machine and or a flat woven braiding sy stem. Although, “braiding”is used, braiding and weaving are a type of interlacing and the terms may be used herein interchangeably. In one or more embodiments, the method includes coating and / or36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION impregnating the multifilament with a coating to enhance abrasion resistance of the multifilament . The coating and method of application may be similar to those described above for the monofilament , with the exception that the coating is applied to the multifilament . The coating may be applied to either the multifilament or at least one of the monofilaments constituting the multifilament .

[0116] Alternatively, in one or more embodiments, the coating is applied to both the multifilament and at least one of the monofilaments constituting the multifilament to achieve desirable physical properties for the multifilament . The coating applied to the multifilament may be the same as or different from the coating applied to the constituent monofilaments. For example, a coating for the monofilaments may be applied for the reduction in friction between the monofilaments and a braiding machine, while a coating for the multifilament may be applied to reduce friction between the lines. In such embodiments, the coating for the multifilament can be different from the coating used for the monofilaments.EXAMPLES

[0117] Abrasion Resistance Test 1

[0118] Abrasion resistance of a commercial LCP monofilament and an inventive LCP monofilament are evaluated. The abrasion test was conducted as described above.

[0119] An example of the inventive LCP monofilament was prepared by the method as described above. Specifically, the inventive LCP was obtained by reacting 4- hydroxybenzoic acid (HBA) monomers and 6-hydroxy-2-naphthoic acid (HNA) monomers with a molar ratio of 70:30.

[0120] A commercial LCP fiber was used to prepare a monofilament as a comparative example. Examples of commercially available LCP fiber include, but are not limited to, Vectran™ HT, NT, and UM (Kuraray Co., Ltd, Japan).

[0121] FIG. 8A shows a digital microscope image of the inventive LCP monofilament and FIG. 8B shows a digital microscope image of the commercial LCP monofilament. The digital microscope used to obtain the image are Olympus DSX1000 Microscope, DSX10-SXLOB Lens IX, Total Magnification 20X. The magnification of the digital microscope images is 10000 pm.

[0122] As shown in FIG. 8A, the inventive LCP monofilament does not show any fibrillation, indicating that the inventive LCP monofilament has high abrasion resistance. Meanwhile, the commercial LCP monofilament (FIG. 8B) shows36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION fibrillation (i.e., a skin layer formed on the surface of the commercial LCP monofilament breaks up into tiny fibrils), indicating poor abrasion resistance.

[0123] Abrasion Resistance Test 2

[0124] Abrasion resistance of a commercial LCP monofilament and an inventive coated-LCP monofilament were evaluated. The abrasion test was conducted as described above.

[0125] An example of the inventive coated-LCP monofilament was prepared by the method as described above. Specifically, the inventive LCP was obtained by reacting 4-hydroxybenzoic acid (HBA) monomers and 6-hydroxy-2-naphthoic acid (HNA) monomers with a molar ratio of 70:30. The obtained LCP was coated with epoxy and silane, where the total amount of epoxy and silane was 3 wt. % based on the weight of the LCP monofilament.

[0126] FIG. 9 shows a digital microscope image of the coated LCP monofilament in accordance with one or more embodiments and a commercial LCP monofilament respectively. The digital microscope used to obtain the image are Olympus DSX1000 Microscope, DSX10-SXLOB Lens IX, Total Magnification 20X. The magnification of the digital microscope image is 10000 pm.

[0127] The inventive coated LCP monofilament is the lower fiber (marked as “901”) shown in FIG. 9. The inventive coated LCP monofilament does not show any fibrillation, indicating that the inventive coated LCP monofilament has high abrasion resistance. The evaluation was concluded when it was determined that the inventive coated LCP monofilament could withstand at least 1000 cycles of wet abrasion and at least 17,156 cycles of dry abrasion. Meanwhile, the commercial LCP monofilament, which is the upper fiber marked as “902” in FIG. 9 shows fibrillation, indicating poor abrasion resistance. The wet abrasion for the commercial LCP monofilament was determined to be 61 cycles.

[0128] Young’s Modulus

[0129] Young’s modulus of the inventive LCP monofilaments are evaluated. The Young’s modulus is measured as described above.

[0130] FIG. 10 is a graph showing Young’s modulus and also tensile stress and maximum force of examples of LCP monofilaments prepared by different process conditions. Example 1 is an inventive LCP monofilament having a diameter of 50 pm prepared with a 0.25 mm sized die, at a die temperature of 340 °C, a draw down ratio36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION(“DDR”) of 25, a line speed of 200 M / min, and quenched with ice after extrusion. Example 2 is another inventive LCP monofilament having a diameter of 50 pm prepared with a 0.15 mm sized die, at a die temperature of 340 °C, a DDR of 9, a line speed of 200 M / min, and quenched with ice after extrusion. Example 3 is another inventive LCP monofilament having a diameter of 50 pm prepared with a 0.15 mm sized die, at a die temperature of 355 °C, a DDR of 9, a line speed of 200 M / min, and quenched with ice after extrusion. Example 4 is another inventive LCP monofilament having a diameter of 72 pm prepared with a 0.25 mm sized die, at a die temperature of 310 °C, a DDR of 12, a line speed of 150 M / min, and quenched with liquid nitrogen (“LN2”) after extrusion. The process conditions for each example are summarized in Table 2 below.

[0131] [Table 2]

[0132] Process Conditions of Examples of Inventive LCP Monofilaments

[0133] Table 3 shows the results of the Young’s modulus test of Examples 1-4.

[0134] [Table 3]

[0135] Results ofYoung’s Modulus Test36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION

[0136] As shown in Table 3 and FIG. 10, Example 1 obtained from the process described above in Table 2, which is equivalent to the conventional method of producing the LCP monofilament, has high Young’s modulus of 81.42 GPa. Such high Young’s modulus makes the LCP monofilament stiff leading to low knot strength. Meanwhile, Example 2, produced with a DDR of 9 (which is lower than that of Example 1) has the Young’s modulus decreased to 53.46 GPa. Example 3 which is produced with higher die temperature (355 °C) compared to Examples 1 and 2 have further decreased Young’s Modulus of 47.08 GPa. Example 4 is produced by lower die temperature, lower DDR, and lower line speed, compared to those of Example 1, has a substantially low Young’s Modulus 68.16 GPa. Decreasing Young’s modulus improves the elongation of the monofilament. The tensile strength also shows similar results as the Young’s modulus, as shown in FIG. 10 and Table 3. The monofilaments of Examples 2-4 are suitable for constituting the braided multifilament article with high strength.

[0137] Tensile Strength vs Tensile Strain

[0138] Stress / strain curves of the inventive LCP monofilament were evaluated. The tensile strength was measured as described above. FIG. 10 is a graph showing tensile stress vs tensile strain of examples of inventive LCP monofilament prepared by different process conditions, and a commercial LCP monofilament.

[0139] Example 1 of the inventive LCP monofilament are prepared by the method as described above. The inventive LCP monofilament in accordance with one or more embodiments has a barrel temperature profile that is profiled differently than conventional polymers. The temperature zones for the feeding, melting, compression and metering zones of the extruder screw are arranged from higher to lower temperatures in a different order than is commonly used for conventional polymers. Specifically, the quenching temperature of an area past an outlet of the extruder die36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION was controlled to be in a range of 0 °C or less and 310 °C or more such to affect the rate of cooling of the LCP monofilament. The line speed was adjusted based on the above quenching temperature. Certain segments within this temperature range are selected for processing the monofilament depending on the resulting properties that are expected in the monofilament.

[0140] Furthermore, the die orifice used to produce the inventive LCP monofilament of one or more embodiments is designed to prevent buildup of the LCP material on the outside of the die opening.

[0141] Comparative Example l is a monofilament using a commercial LCP. Examples of commercially available LCP include, but are not limited to, Vectran™ HT, NT, and UM (Kuraray Co., Ltd, Japan).

[0142] As shown in FIG. 11, the commercial LCP monofilament has a tensile elongation of less than 5%. Meanwhile, Example 1 has a tensile elongation of greater than 7%, which improves the flexibility and ability of the monofilament to be interlaced into multifilament articles.

[0143] In another experiment, the effect of post extrusion cooling was studied by varying the cooling temperature and examining the skin layer of the resulting monofilament.

[0144] Table 4 Examination of skin layer

[0145] The monofilament in Example 5 was heated during its post extrusion cooling which resulted in the creation of a corresponding thicker skin thickness compared to the monofilament of Example 6 which was allowed to cool at room temperature. Both samples were subjected to abrasion testing with Example 5 performing much better than comparative Example 6. The Hermans orientation factor (HOF) was also determined from X-ray diffraction measurements. HOF is a scalar giving a simple36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION assessment of molecular or crystal orientation in a polymer. As detailed in Table 4, the crystallinity of Sample 5 was more ordered than comparative Example 6, which may also contribute to its increased abrasion resistance.

[0146] Further investigation of post extrusion heating (PEH) and monofilament coating was conducted by subjecting multiple samples to a variety of various heating temperatures and methods, while also combining coating via multiple methods. All samples were evaluated using the abrasion testing described in previous examples.

[0147] Table 5 Abrasion resistant monofilament testing

[0148] Examples 7 through 14 included testing on 75 micron monofilaments which were all extruded via the same method. Two methods of post extrusion heating were used and two methods of monofilament coatings were used. The effect of temperature of post extrusion heating was investigated and a post curing technique was also36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATION employed after reaching room temperature in which samples were maintained at 120 C for 24 hours.

[0149] In Examples 7 through 11, PEH was conducted at increasing temperatures. No post curing was conducted on these samples. As detailed in Table 5, abrasion resistance increased with increased PEH temperatures. It is believed that such increased PEH results in increased skin thickness and crystalline order.

[0150] In example 12, the monofilament was coated with PDMS using the coating method described herein. A subset of samples were subjected to abrasion testing and a four fold increase in abrasion resistance was observed. Another subset of samples was cured at 120 C, allowed to cool and then subjected to abrasion resistance testing. A significant increase in abrasion resistance was again observed. This subsequent increase in abrasion resistance is understood as resulting from both an improved coating layer and increased skin layer abrasion resistance.

[0151] In example 13, the monofilament was compounded with 7 wt% PDMS using the compounding method described herein. A subset of samples were subjected to abrasion testing and a threefold increase in abrasion resistance was observed. Another subset of samples was cured at 120 C, allowed to cool and then subjected to abrasion resistance testing. A significant increase in abrasion resistance was again observed equal to the coated Example 12. This subsequent increase in abrasion resistance is understood as both improved coating layer and increased skin layer abrasion resistance.

[0152] In example 14, the monofilament was compounded with 5 wt% PDMS using the compounding method described herein. The compounded resin was extruded and then heated at 300C. A subset of samples were subjected to abrasion testing and a sixteen fold increase in abrasion resistance was observed relative the control Example 7. Another subset of samples was cured at 120 C, allowed to cool and then subjected to abrasion resistance testing. Degradation in abrasion resistance was observed. This subsequent decrease in abrasion resistance, although not desirable, demonstrates a different effect of the post curing method, but still resulted in increased abrasion resistance.

[0153] A variety of monofilaments corresponding to Examples 8 through 14 were interlaced on industrial equipment to test their resistance to associated abrasion caused by the weaving equipment. The strength, flexibility, and abrasion resistance of the monofilaments resulted in successful interlaced articles of various designs.36819143.2PCT / US25 / 46526 16 September 2025 (16.09.2025)ZP-003 PCT PATENT APPLICATIONSpecifically, woven articles were produced wherein the weft and warp were the same monofilaments, and in other aspects where the weft and warp comprised different monofilaments. In all aspects, the resulting woven articles were free from fibrillation and otherwise manufactured by standard weaving industrial methods.

[0154] Embodiments of the present disclosure may provide at least one of the following advantages.

[0155] Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.36819143.2

Claims

ZP-003 PCT PATENT APPLICATIONCLAIMSWhat is claimed:

1. A monofilament comprising: a liquid crystal polymer formed from a reaction selected from the group consisting of (i) a polycondensation reaction between aromatic hydroxycarboxylic acids; and (ii) a polycondensation reaction between an aromatic hydroxy carboxylic acid and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aliphatic carboxylic acids, aromatic hydroxyamines, aromatic diamines, aromatic diols, and aliphatic diols, and wherein the monofilament has a tensile strength in a range from 700 MPa to 3100 MPa.

2. The monofilament of claim 1, wherein the monofilament has elongation in a range of 4% to 30%.

3. The monofilament of claim 1, wherein the monofilament has a tensile strength of in a range of 2200 MPa to 3100 MPa.

4. The monofilament of claim 1. wherein the monofilament has a tensile elongation in a range of 4% to 40%.

5. The monofilament of claim 1, wherein the monofilament has a Young’s modulus in a range of 1 GPa to 120 GPa.

6. The monofilament of claim 1, wherein the monofilament has wet abrasion cycle in a range of 200 times to 2100 times.

7. The monofilament of claim 1, wherein the monofilament absorbs 0.04 wt% or less of water.

8. The monofilament of claim 1, wherein the monofilament has dry abrasion cycle of 200 times or more.

9. The monofilament of claim 1, wherein the monofilament has a friction coefficient in a range of 0.1 to 3.86.

10. The monofilament of claim 1, wherein the monofilament has a skin layer thickness in a range of 100 to 500 nm.

11. The monofilament of claim 1, wherein the liquid crystal polymer has a molecular weight in a range of 5400 Da to 17000 Da.

12. The monofilament of claim 1 , wherein a molar ratio between aromatic hydroxy carboxylic acids and the at least one comonomer ranges from 80:20 to 70:30.

13. The monofilament of claim 1. wherein the monofilament is coated, and the coating is selected from a group consisting of glycidyl epoxy, novolac epoxy, cycloaliphatic epoxy.36819143.2 32ZP-003 PCT PATENT APPLICATION aromatic epoxy, siloxane, silicon carbide filled epoxy, PDMS and urethane and combinations thereof.

14. A multifilament comprising: a braided or twisted article comprising a plurality of monofilaments braided or twisted to form the braided or twisted article, wherein the plurality of monofilaments comprises a liquid crystal polymer formed from a reaction selected from the group consisting of (i) a polycondensation reaction between one or more aromatic hydroxy carboxylic acids; and (ii) a polycondensation reaction between an aromatic hydroxycarboxylic acid and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aliphatic carboxylic acids, aromatic hydroxyamines, aromatic diamines, aromatic diols, and aliphatic diols, and wherein the multifilament has a knot strength ranging from 500 to 2,000 MPa.

15. The multifilament of claim 14, wherein the multifilament has wet abrasion cycle ranging from 400 times to 2,000 times.

16. The multifilament of claims 14 or 15, wherein the multifilament has afriction coefficient ranging from 0.1 to 3.86.

17. The multifilament of any one of the preceding claims 14 to 16, wherein at least one of the plurality of monofilaments has a skin layer thickness of 500 nm or less.

18. The multifilament of any one of the preceding claims 14 to 17, wherein the braided article has a fineness ranging from 60 dtex to 2,000 dtex.

19. The multifilament of any one of the preceding claims 14 to 18, wherein the multifilament has a tensile strength ranging from 1,400 MPa to 3,000 MPa.

20. The multifilament of any one of the preceding claims 14 to 19. wherein the multifilament has a Young’s modulus of greater than 30 GPa.

21. The multifilament of any one of the preceding claims 14 to 20, wherein the multifilament has a tensile elongation ranging from 1.8% to 6.0%.

22. The multifilament of any one of the preceding claims 14 to 21, wherein the multifilament has a knot elongation ranging from 1.0% to 6.0%.

23. The multifilament of any one of the preceding claims 14 to 22. wherein the multifilament absorbs 0.04 wt% or less of water.

24. The multifilament of any one of the preceding claims 14 to 23, wherein a molar ratio between aromatic hydroxy carboxylic acids and the at least one comonomer ranges from 80:20 to 70:30.36819143.2ZP-003 PCT PATENT APPLICATION25. The multifilament of any one of the preceding claims 14 to 24, wherein the liquid crystal polymer comprises an additive selected from the group consisting of glycidyl epoxy, novolac epoxy, cycloaliphatic epoxy, aromatic epoxy, silane and combinations thereof.

26. The multifilament of any one of the preceding claims 14 to 25, wherein the plurality of monofilaments and / or the multifilament are coated with a coating selected from the group consisting of siloxane, silicon carbide-filled epoxy, and urethane, wherein the coating optionally contains a lubricant.

27. The multifilament of any one of the preceding claims 14 to 26, wherein the plurality of monofilaments each have a diameter ranging from 10 to 800 pm.

28. The multifilament of any one of the preceding claims 14 to 27, wherein the braided or twisted article has a carrier count ranging from 4 to 54.

29. The multifilament of any one of the preceding claims 14 to 28, wherein the braided or twisted article has picks per inch (PPI) ranging from 2 to 12.

30. The multifilament of any one of the preceding claims 14 to 29, wherein the braided or twisted article has a braiding angle ranging from 10 degrees to 45 degrees.

31. A method of producing a multifilament article having at least one monofilament, comprising: polymerizing monomers to form a liquid cry stal polymer; melting the liquid cry stal polymer to form a molten liquid crystal polymer; extruding the molten liquid crystal polymer to form an extruded liquid crystal polymer; and drawing the extruded liquid crystal polymer to form a monofilament having a diameter ranging from 10 to 800 pm.

32. The method of claim 31, further comprising the step of braiding or twisting the at least one monofilament to form the multifilament .

33. The method of claim any7one of 31 to 32, wherein the monomers are selected from the group consisting of (i) one or more aromatic hydroxycarboxylic acids; and (ii) an aromatic hydroxycarboxylic acid and at least one comonomer selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, aromatic hydroxyamines, aromatic diamines, aromatic diols, and aliphatic diols.

34. The method of claim 31, wherein the polymerizing comprises a condensation polymerization.

35. The method of claims any one of 31 to 34, wherein the melting further comprises adding an additive to the molten liquid crystal polymer.36819143.2 34ZP-003 PCT PATENT APPLICATION36. The method of any one of claims 31 to 35, wherein the method further comprises adding an additive during the extruding or after the extruding.

37. The method of claim 36, wherein the additive is selected from the group consisting of glycidyl epoxy, novolac epoxy, cycloaliphatic epoxy, aromatic epoxy, silane, and combinations thereof.

38. The method of claim 37, further comprising coating the monofilament with a coating selected from the group consisting of siloxane, silicon carbide-filled epoxy, and urethane, wherein the coating optionally contains a lubricant.

39. The method of any one of claims 31 to 37, further comprising coating the multifilament with a coating selected from the group consisting of siloxane, silicon carbide-filled epoxy, and urethane, wherein the coating optionally contains a lubricant.

40. The method of any one of claims 31 to 34, wherein the extruding is performed at an extrusion temperature ranging from 280 °C to 360 °C.

41. The method of any one of claims 31 to 34, wherein the extruding is performed at an extrusion speed ranging from 50 to 750 m / min.

42. The method of any one of claims 31 to 34, wherein the drawing is performed at a draw ratio ranging from 9 to 156.

43. The method of claim 42, wherein the drawing is performed at a drawing speed ranging from 50 to 750 m / min.

44. The method of claim 37 further comprising a step of interlacing the monofilament to form a multifilament.

45. The method of claim 44, wherein the interlacing step comprises a weaving process in which a plurality of first monofilaments is used as weft and a plurality of second monofilaments is used as warp.

46. The method of claim 45 wherein the first monofilaments and second monofilaments are different.

47. The method of claim 46, further comprising a step of interlacing the monofilament to form a multifilament.

48. The method of claim 47. further comprising an additive removal step wherein the multifilament is exposed to a solvent which can remove at least a portion of the additive from each monofilament after the interlacing step.36819143.2 35

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