Polyester monofilaments

Abstract

The present invention provides monofilaments coated with certain adhesive layers and methods to produce the coated filaments. Also provided are fabrics formed from the monofilaments. The coated monofilaments and fabrics provide improved adhesion with additional coating top layers.

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       4 . A monofilament comprising a polyester core and a core coating, wherein said core coating comprises a vinylidene chloride copolymer, and wherein said vinylidene chloride copolymer comprises 35 to 96 weight percent vinylidene chloride, from about 3.5 to about 64.5 weight percent of an acrylic ester, and from about 0.5 to about 25 weight percent of itaconic acid based on weight of copolymer.  
   
   
       5 . The monofilament of  claim 4  wherein said vinylidene chloride copolymer comprises about 75 to about 95 weight percent vinylidene chloride, about 4 to about 20 weight percent of an acrylic ester, and about 1 to about 5 weight percent of itaconic acid based on weight of copolymer.  
   
   
       6 . The monofilament of  claim 4  wherein said acrylic ester is selected from alkyl esters of acrylic acid or methacrylic acid with 1 to 18 carbon atoms in the alkyl group.  
   
   
       7 . The monofilament of  claim 4  wherein said vinylidene chloride copolymer is blended with a polyacrylate ester.  
   
   
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       13 . A textile fabric comprising the polyester monofilament of  claim 4 .  
   
   
       14 . A textile fabric comprising a polyester monofilament and a fabric coating of a vinylidene chloride.  
   
   
       15 . The textile fabric of  claim 14  wherein the polyester monofilament comprises a polyester core and a core coating, said core coating comprising a vinylidene chloride copolymer.  
   
   
       16 . The textile fabric of  claim 14  wherein said vinylidene chloride copolymer comprises from about 35 to about 96 weight percent vinylidene chloride and from about 4 to about 65 weight percent of at least one other polymerizable olefin monomer based on weight of copolymer.  
   
   
       17 . The textile fabric of  claim 14  wherein said vinylidene chloride copolymer comprises about 35 to about 96 weight percent vinylidene chloride, about 3.5 to about 64.5 weight percent of an acrylic ester, and about 0.5 to about 25 weight percent of itaconic acid based on weight of copolymer.  
   
   
       18 . The textile fabric of  claim 14  wherein said vinylidene chloride copolymer comprises about 75 to about 95 weight percent vinylidene chloride, about 4 to about 20 weight percent of an acrylic ester, and about 1 to about 5 weight percent of itaconic acid based on weight of copolymer.  
   
   
       19 . The textile fabric of  claim 18  wherein said acrylic ester is selected from alkyl esters of acrylic acid or methacrylic acid with 1 to 18 carbon atoms in the alkyl group.  
   
   
       20 . The textile fabric of  claim 14  wherein said vinylidene chloride copolymer is blended with a polyacrylate ester.  
   
   
       21 . The textile fabric of  claim 14  comprising a second coating, said second coating being selected from the group consisting of fluorinated surfactants.  
   
   
       22 . The textile fabric of  claim 14  comprising a second coating, said second coating being selected from the group consisting of polyolefins, cyclic olefin polymers, modified polyolefins, polyolefin copolymers, glycidyl esters of unsaturated acids, ionomers, ethylene/vinyl copolymers, ethylene/vinyl chloride copolymers, ethylene/vinyl acetate copolymers, ethylene/acrylic acid copolymers, ethylene/methacrylic acid copolymers, ethylene/vinyl alcohol copolymers, poly(vinyl alcohol), poly(vinyl alcohol-cobutyral), polyurethanes, thermoplastic polyurethanes, polyvinyl chloride, polyvinylidene chloride copolymers, liquid crystalline polymers, fluorinated polymers, polyamides, polyimides, polyphenylene sulfide, polyphenylene oxide, polysulfones, polyethersulfones, rubbers, polycarbonate, polyacrylates, terpene resins, polyacetal, styrene/acrylonitrile copolymers, styrene/maleic anhydride copolymers, styrene/maleimide copolymers, coumarone/indene copolymers, and combinations thereof.  
   
   
       23 . A process for producing a polyester monofilament comprising a polyester core and a vinylidene chloride copolymer coating, said process comprising: providing a polyester monofilament and depositing onto said polyester monofilament a vinylidene chloride copolymer to form said coating, drawing coated polyester monofilament to a draw ratio from about 3.0:1 to about 6.5:1 at a temperature up to about 250° C.  
   
   
       24 . The process of  claim 23 , wherein the polyester monofilament is drawn at a temperature up to about 100° C. to a length corresponding to a draw ratio of about 3.0:1 to about 4.5:1.  
   
   
       25 . The process of  claim 23  wherein, following said drawing, the polyester monofilament is allowed to relax to about 30 percent of its drawn length.  
   
   
       26 . The process of  claim 23 , further comprising depositing onto said coated polyester monofilament a second coating.  
   
   
       27 . A process for producing a textile fabric comprising providing a textile fabric made from polyester monofilament, depositing onto said polyester monofilament textile fabric a vinylidene chloride copolymer to form a coating, and subjecting coated fabric to a temperature up to about 250° C.  
   
   
       28 . The process of  claim 27  wherein after coating is applied, a vacuum is applied across the fabric and coated fabric is subjected to a temperature up to about 250° C.  
   
   
       29 . The process of  claim 27  wherein after coating is applied, a pressure is applied across the fabric and coated fabric is subjected to a temperature up to about 250° C.  
   
   
       30 . The process of  claim 28  wherein the textile fabric comprises a woven polyester monofilament textile fabric.  
   
   
       31 . The process of  claim 28  comprising depositing onto one or more first coatings of a vinylidene chloride copolymer, and a second coating, the second coating being applied after subjecting fabric to temperature up to about 250° C. for sufficient time to dry first coating of vinylidene chloride copolymer.  
   
   
       32 . The process of  claim 29  wherein the textile fabric comprises a woven polyester monofilament textile fabric.  
   
   
       33 . The process of  claim 29  comprising depositing onto one or more first coatings of a vinylidene chloride copolymer, and a second coating, the second coating being applied after subjecting fabric to temperature up to about 250° C. for sufficient time to dry first coating of vinylidene chloride copolymer.