Thermoplastic Elastomer-Based Multifilament Yarn

Abstract

A thermoplastic elastomer-based multifilament yarn and a method of making a thermoplastic elastomer-based multifilament yarn are disclosed. The multifilament yarn comprises a first filament that is at least partially adhered to a second filament. The first filament and the second filament are each formed from 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 has a linear density of from about 1 to about 500 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 multifilament yarn comprising a first filament that is at least partially adhered to a second filament, wherein the first filament and the second filament are each formed from 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 has a linear density of from about 1 to about 500 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. 
     
     
         2 . The multifilament yarn of  claim 1 , wherein the multifilament 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 multifilament yarn of  claim 1 , wherein the multifilament 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 multifilament yarn of  claim 1 , wherein the multifilament yarn exhibits a recoverable stretch of at least about 75%, as determined in accordance with ASTM D6720-07 (2018). 
     
     
         5 . The multifilament 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 multifilament yarn of  claim 1 , wherein the thermoplastic elastomer is a thermoplastic copolyetherester elastomer. 
     
     
         7 . The multifilament 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 multifilament 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 multifilament 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 multifilament 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 multifilament 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 multifilament 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 multifilament yarn of  claim 1 , wherein the first filament and the second filament are coated with a finish. 
     
     
         14 . The multifilament yarn of  claim 13 , wherein the finish comprises a finish oil comprising a silicone oil. 
     
     
         15 . The multifilament yarn of  claim 13 , wherein the finish coats at least about 50% of a surface area of the first filament and the second filament. 
     
     
         16 . The multifilament yarn of  claim 1 , wherein the multifilament yarn further comprises a third filament at least partially adhered to the first filament, the second filament, or both. 
     
     
         17 . The multifilament yarn of  claim 16 , wherein the first filament, the second filament, and the third filament are at least partially adhered to each other. 
     
     
         18 . A method of making the multifilament yarn of  claim 1 , the method comprising:
 extruding a melt comprising the thermoplastic elastomer composition comprising the thermoplastic elastomer through a spinneret;   withdrawing a first filament and a second filament from the spinneret to a feed roller;   quenching the first filament and the second filament using air;   applying a finish to the first filament and the second filament; and   collecting the first filament and the second filament on a winding roller.   
     
     
         19 . The method of  claim 18 , further comprising:
 drawing the first filament and the second filament using a draw roller.   
     
     
         20 . The method of  claim 19 , wherein a feed roller speed is greater than a draw roller speed and/or wherein a draw roller speed is greater than a winding roller speed.