Thermoplastic Elastomer-Based Monofilament Yarn

Abstract

A thermoplastic elastomer-based monofilament yarn and a method of making a thermoplastic elastomer-based monofilament yarn are disclosed. The monofilament yarn comprises a filament that contains an axial core about which two or more lobes are radially disposed. The filament comprises a thermoplastic elastomer composition comprising a thermoplastic elastomer that exhibits a flexural modulus of about 300 MPa or less as determined in accordance with ISO 178:2019 at a temperature of about 23° C. The yarn exhibits a linear density of from about 1 to about 2000 denier per filament and exhibits an elongation at break of about 300% or more as determined in accordance with ASTM D2653-07 (2018) at a temperature of about 23° C.

What is claimed is: 
     
         1 . A monofilament yarn comprising a filament that contains an axial core about which two or more lobes are radially disposed, wherein the filament comprises a thermoplastic elastomer composition comprising a thermoplastic elastomer that exhibits a flexural modulus of about 300 MPa or less as determined in accordance with ISO 178:2019 at a temperature of about 23° C. and further wherein the yarn exhibits a linear density of from about 1 to about 2000 denier per filament and an elongation at break of about 300% or more as determined in accordance with ASTM D2653-07 (2018) at a temperature of about 23° C. 
     
     
         2 . The monofilament yarn of  claim 1 , wherein the monofilament yarn exhibits a shrinkage of about 50% or less as determined in accordance with ASTM D2259-02 (2016) (Section 6.6.1—dry heat exposure). 
     
     
         3 . The monofilament yarn of  claim 1 , wherein the monofilament yarn exhibits a tenacity of about 0.7 grams per denier or more as determined in accordance with ASTM D2653-07 (2018) at a temperature of about 23° C. 
     
     
         4 . The monofilament yarn of  claim 1 , wherein the monofilament yarn exhibits a recoverable stretch of at least about 75%, as determined in accordance with ASTM D6720-07 (2018). 
     
     
         5 . The monofilament yarn of  claim 1 , wherein the thermoplastic elastomer exhibits one or more of a Shore D hardness of about 60 or less, as determined in accordance with ISO 868:2003 (test time of 15 seconds) at a temperature of about 23° C., a melting temperature of from about 100° C. to about 230° C., as determined in accordance with ISO 11357-3:2018, or a tensile stress at break of about 45 MPa or less, as determined in accordance with ISO 527-1/-2 (2012) at a temperature of about 23° C. 
     
     
         6 . The monofilament yarn of  claim 1 , wherein the thermoplastic elastomer is a thermoplastic copolyetherester elastomer. 
     
     
         7 . The monofilament yarn of  claim 1 , wherein the thermoplastic elastomer is a thermoplastic copolyester elastomer containing hard segments and soft segments, wherein the hard segments constitute from about 20 wt. % or more to about 70 wt. % or less of the thermoplastic copolyester elastomer and the soft segments constitute from about 30 wt. % or more to about 80 wt. % or less of the thermoplastic copolyester elastomer. 
     
     
         8 . The monofilament yarn of  claim 1 , wherein the thermoplastic elastomer is a thermoplastic copolyester elastomer containing hard segments and soft segments, wherein the hard segments are derived from at least one aromatic dicarboxylic acid and/or a diester thereof and at least one diol containing from 2 to 15 carbon atoms. 
     
     
         9 . The monofilament yarn of  claim 8 , wherein the aromatic dicarboxylic acid includes terephthalic acid, isophthalic acid, or a combination thereof and wherein the diol includes ethylene glycol, 1,4 butanediol, 1,3-propane diol, or a combination thereof. 
     
     
         10 . The monofilament yarn of  claim 1 , wherein the thermoplastic elastomer is a thermoplastic copolyester elastomer containing hard segments and soft segments, wherein the soft segments are derived from at least one aromatic dicarboxylic acid and/or a diester thereof and at least one poly(alkylene oxide) glycol. 
     
     
         11 . The monofilament yarn of  claim 10 , wherein the aromatic dicarboxylic acid includes terephthalic acid, isophthalic acid, or a combination thereof and wherein the poly(alkylene oxide) glycol includes 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 monofilament yarn of  claim 1 , wherein the thermoplastic elastomer comprises a thermoplastic copolyetherester elastomer prepared from monomers 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 monofilament yarn of  claim 1 , wherein the filament is coated with a finish and wherein the finish coats at least about 50% of a surface area of the filament. 
     
     
         14 . The monofilament yarn of  claim 1 , wherein the filament is coated with a finish comprising a finish oil comprising a silicone oil. 
     
     
         15 . The monofilament yarn of  claim 1 , wherein the two or more lobes comprise a convex curve. 
     
     
         16 . The monofilament yarn of  claim 1 , wherein the two or more lobes are connected to each other at a cusp. 
     
     
         17 . The monofilament yarn of  claim 1 , wherein the filament contains at least three lobes disposed radially about the axial core. 
     
     
         18 . The monofilament yarn of  claim 17 , wherein the axial core is hollow. 
     
     
         19 . The monofilament yarn of  claim 17 , wherein the axial core comprises the thermoplastic elastomer composition. 
     
     
         20 . A method of making the monofilament yarn of  claim 1 , the method comprising:
 extruding a melt comprising the thermoplastic elastomer composition comprising the thermoplastic elastomer through a spinneret;   withdrawing a filament from the spinneret to a feed roller;   quenching the filament using air;   applying a finish to the filament; and   collecting the filament on a winding roller.