US2002010303A1PendingUtilityA1

Novel melt-spun elastomeric fibers and the preparation thereof

46
Priority: Sep 16, 1997Filed: Jul 3, 2001Published: Jan 24, 2002
Est. expirySep 16, 2017(expired)· nominal 20-yr term from priority
Inventors:Robert P. Foss
C08L 75/08Y10S528/906D01F 6/70C08G 18/12C08G 18/6677C08G 18/2036Y10T428/2913C08G 18/2081C08G 18/10
46
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Claims

Abstract

Novel melt-spun elastomeric fibers and methods for their preparation. Embodiments are provided in which fibers are melt-spun from a melt-spinnable elastomeric polymer comprising a diisocyanate-capped polyol prepolymer which is chain-extended with an aromatic dihydroxy compound. Also provided are melt-spinnable elastomeric polymers and prepolymers therefor. The fibers may be knit or woven into textile articles including, inter alia, hosiery and pantyhose.

Claims

exact text as granted — not AI-modified
What is claimed:  
     
         1 . A melt-spun fiber which is prepared from a melt-spinnable elastomeric polymer having the formula:  
       [Pr—Ar] n   (I)  
       wherein: 
 n is from about 30 to about 65;  
 Ar is a residue of an aromatic dihydroxy compound; and  
 Pr is a prepolymer which comprises: 
 from about 85 to about 95 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 15 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 2 mole % of a prepolymer component of formula T-G-T-G-T-G-T, wherein:  
 G is a residue of a polyol; and  
 T is a residue of a diisocyanate compound;  
 wherein in the preparation of the melt-spinnable elastomeric polymer, which preparation comprises combining together said polyol, said diisocyanate compound and said aromatic dihydroxy compound, said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide the melt-spinnable elastomeric polymer with substantially no higher melting polymeric component.  
 
 
     
     
         2 . A melt-spun fiber according to  claim 1  wherein the melt-spinnable elastomeric polymer contains less than about 5% by weight of higher melting polymeric component.  
     
     
         3 . A melt-spun fiber according to  claim 2  wherein the melt-spinnable elastomeric polymer contains less than about 4% by weight of higher melting polymeric component.  
     
     
         4 . A melt-spun fiber according to  claim 3  wherein the melt-spinnable elastomeric polymer contains less than about 3% by weight of higher melting polymeric component.  
     
     
         5 . A melt-spun fiber according to  claim 4  wherein the melt-spinnable elastomeric polymer contains less than about 2% by weight of higher melting polymeric component.  
     
     
         6 . A melt-spun fiber according to  claim 5  wherein the melt-spinnable elastomeric polymer contains less than about 1% by weight of higher melting polymeric component.  
     
     
         7 . A melt-spun fiber according to  claim 1  wherein n is from about 33 to about 56.  
     
     
         8 . A melt-spun fiber according to  claim 7  wherein n is from about 37 to about 54.  
     
     
         9 . A melt-spun fiber according to  claim 8  wherein n is from about 40 to about 50.  
     
     
         10 . A melt-spun fiber according to  claim 1  wherein said aromatic dihydroxy compound is selected from the group consisting of 1,4-bis(β-hydroxyethoxy)benzene, bis(β-hydroxyethoxy)terephthalate and p-xylylenediol.  
     
     
         11 . A melt-spun fiber according to  claim 10  wherein said aromatic dihydroxy compound is 1,4-bis(β-hydroxyethoxy)benzene.  
     
     
         12 . A melt-spun fiber according to  claim 1  wherein said prepolymer comprises: 
 from about 90 to about 94 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 7 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 1 mole % of a prepolymer component of formula T-G-T-G-T-G-T.  
 
     
     
         13 . A melt-spun fiber according to  claim 12  wherein said prepolymer comprises: 
 from about 92 to about 94 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 5 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 0.5 mole % of a prepolymer component of formula T-G-T-G-T-G-T.  
 
     
     
         14 . A melt-spun fiber according to  claim 1  wherein said diisocyanate compound is selected from the group consisting of aromatic diisocyanate compounds and aliphatic diisocyanate compounds.  
     
     
         15 . A melt-spun fiber according to  claim 14  wherein said diisocyanate compound comprises an aromatic diisocyanate compound.  
     
     
         16 . A melt-spun fiber according to  claim 15  wherein said aromatic diisocyanate compound is selected from the group consisting of diphenylmethane diisocyanate, xylene diisocyanate, toluene diisocyanate, phenylene diisocyanate, and naphthaiene diisocyanate.  
     
     
         17 . A melt-spun fiber according to  claim 16  wherein said diisocyanate compound is diphenylmethane diisocyanate.  
     
     
         18 . A melt-spun fiber according to  claim 14  wherein said diisocyanate compound comprises an aliphatic diisocyanate compound.  
     
     
         19 . A melt-spun fiber according to  claim 18  wherein said aliphatic diisocyanate compound is selected from the group consisting of dicyclohexylmethane diisocyanate and hexamethylene diisocyanate.  
     
     
         20 . A melt-spun fiber according to  claim 1  wherein said polyol comprises a polymeric diol.  
     
     
         21 . A melt-spun fiber according to  claim 20  wherein said polymeric diol is selected from the group consisting of a polyether diol and a polyester diol.  
     
     
         22 . A melt-spun fiber according to  claim 21  wherein said polymeric diol is a polyether diol.  
     
     
         23 . A melt-spun fiber according to  claim 22  wherein said polyether diol is a polyalkylene ether diol.  
     
     
         24 . A melt-spun fiber according to  claim 23  wherein said polyalkylene ether diol is selected from the group consisting of polyethylene ether glycol, polypropylene ether glycol, polytetramethylene ether glycol and polyhexamethylene ether glycol and copolymers thereof.  
     
     
         25 . A melt-spun fiber according to  claim 24  wherein said polyalkylene ether diol is polytetramethylene ether glycol.  
     
     
         26 . A melt-spun fiber according to  claim 21  wherein said polymeric diol is a polyester diol.  
     
     
         27 . A melt-spun fiber according to  claim 26  wherein said polyester diol is selected from the group consisting of polybutylene adipate glycol and polyethylene adipate glycol and copolymers thereof.  
     
     
         28 . A fiber which is melt-spun from a melt-spinnable elastomeric polymer, wherein the melt-spinnable elastomeric polymer comprises a diisocyanate-capped polyol prepolymer which is chain-extended with an aromatic dihydroxy compound, wherein in the preparation of said melt-spinnable elastomeric polymer. which preparation comprises combining together said polyol, said diisocyanate compound and said aromatic dihydroxy compound, said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide the melt-spinnable elastomeric polymer with substantially no higher melting polymeric component.  
     
     
         29 . A fiber according to  claim 28  wherein said preparation of said melt-spinnable elastomeric polymer comprises: 
 (a) combining together said polyol and said diisocyanate compound to provide said prepolymer containing substantially no unreacted diisocyanate compound; and  
 (b) combining together said prepolymer and said aromatic dihydroxy compound to provide said melt-spinnable elastomeric compound.  
 
     
     
         30 . A fiber according to  claim 29  wherein said prepolymer contains less than about 4 mole % unreacted diisocyanate compound.  
     
     
         31 . A fiber according to  claim 30  wherein said prepolymer contains less than about 3 mole % unreacted diisocyanate compound.  
     
     
         32 . A fiber according to  claim 31  wherein said prepolymer contains less than about 2 mole % unreacted diisocyanate compound.  
     
     
         33 . A fiber according to  claim 32  wherein said prepolymer contains less than about 1 mole % unreacted diisocyanate compound.  
     
     
         34 . A method for the preparation of a melt-spun fiber comprising providing a melt-spinnable elastomeric polymer having the formula:  
       [Pr—Ar] n   (I)  
       wherein: 
 n is from about 30 to about 65;  
 Ar is a residue of an aromatic dihydroxy compound; and  
 Pr is a prepolymer which comprises: 
 from about 85 to about 95 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 15 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 2 mole % of a prepolymer component of formula T-G-T-G-T-G-T, wherein:  
 G is a residue of a polyol; and  
 T is a residue of a diisocyanate compound; and  
 
 melt spinning said melt-spinnable elastomeric polymer; wherein said melt-spinnable elastomeric polymer is prepared by a method which comprises combining together said polyol, said diisocyanate compound and said aromatic dihydroxy compound, wherein said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide the melt-spinnable elastomeric polymer with substantially no higher melting polymeric component.  
 
     
     
         35 . A method according to  claim 34  wherein said melt-spinnable elastomeric polymer is prepared by a method which comprises: 
 (a) combining together said polyol and said diisocyanate compound to provide said prepolymer containing substantially no unreacted diisocyanate compound; and  
 (b) combining together said prepolymer and said aromatic dihydroxy compound to provide said melt-spinnable elastomeric polymer.  
 
     
     
         36 . A method according to  claim 34  wherein n is from about 33 to about 56.  
     
     
         37 . A method according to  claim 36  wherein n is from about 37 to about 54.  
     
     
         38 . A method according to  claim 37  wherein n is from about 40 to about 50.  
     
     
         39 . A method according to  claim 35  wherein said aromatic dihydroxy compound is selected from the group consisting of 1,4-bis(β-hydroxy-ethoxy)benzene, bis(β-hydroxyethoxy)terephthalate and p-xylylenediol.  
     
     
         40 . A method according to  claim 39  wherein said aromatic dihydroxy compound is 1,4-bis(β-hydroxyethoxy)benzene.  
     
     
         41 . A method according to  claim 35  wherein said prepolymer comprises: 
 from about 90 to about 94 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 7 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 1 mole % of a prepolymer component of formula T-G-T-G-T-G-T.  
 
     
     
         42 . A method according to  claim 41  wherein said prepolymer comprises: 
 from about 92 to about 94 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 5 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 0.5 mole % of a prepolymer component of formula T-G-T-G-T-G-T.  
 
     
     
         43 . A method according to  claim 35  wherein said diisocyanate compound is selected from the group consisting of aromatic diisocyanate compounds and aliphatic diisocyanate compounds.  
     
     
         44 . A method according to  claim 43  wherein said diisocyanate compound comprises an aromatic diisocyanate compound.  
     
     
         45 . A method according to  claim 44  wherein said aromatic diisocyanate compound is selected from the group consisting of diphenylmethane diisocyanate, xylene diisocyanate, toluene diisocyanate, phenylene diisocyanate, and naphthalene diisocyanate.  
     
     
         46 . A method according to  claim 45  wherein said diisocyanate compound is diphenylmethane diisocyanate.  
     
     
         47 . A method according to  claim 43  wherein said diisocyanate compound comprises an aliphatic diisocyanate compound.  
     
     
         48 . A method according to  claim 47  wherein said aliphatic diisocyanate compound is selected from the group consisting of dicyclohexylmethane diisocyanate and hexamethylene diisocyanate.  
     
     
         49 . A method according to  claim 35  wherein said polyol comprises a polymeric dial.  
     
     
         50 . A method according to  claim 49  wherein said polymeric diol is selected from the group consisting of a polyether diol and a polyester diol.  
     
     
         51 . A method according to  claim 50  wherein said polymeric diol is a polyether diol.  
     
     
         52 . A method according to  claim 51  wherein said polyether diol is a polyalkylene ether diol.  
     
     
         53 . A method according to  claim 52  wherein said polyalkylene ether diol is selected from the group consisting of polyethylene ether glycol, polypropylene ether glycol, polytetramethylene ether glycol and polyhexamethylene ether glycol and copolymers thereof.  
     
     
         54 . A method according to  claim 53  wherein said polyalkylene ether diol is polytetramethylene ether glycol.  
     
     
         55 . A method according to  claim 50  wherein said polymeric diol is a polyester diol.  
     
     
         56 . A method according to  claim 55  wherein said polyester diol is selected from the group consisting of polybutylene adipate glycol and polyethylene adipate glycol and copolymers thereof.  
     
     
         57 . A method for the preparation of a melt-spun fiber comprising: 
 providing a melt-spinnable elastomeric polymer which comprises a diisocyanate-capped polyol prepolymer which is chain-extended with an aromatic dihydroxy compound, wherein said melt-spinnable elastomeric polymer is prepared by a method comprising combining together said polyol, said diisocyanate compound and said aromatic dihydroxy compound, wherein said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide said melt-spinnable elastomeric polymer with substantially no higher melting polymeric component; and    melt spinning said melt-spinnable elastomeric polymer to provide the fiber.    
     
     
         58 . A method according to  claim 57  wherein said melt-spinnable elastomeric polymer is prepared by a method which comprises: 
 (a) combining together said polyol and said diisocyanate compound to provide said prepolymer containing substantially no unreacted diisocyanate compound: and  
 (b) combining together said prepolymer and said aromatic dihydroxy compound to provide said melt-spinnable elastomeric polymer.  
 
     
     
         59 . A melt-spinnable elastomeric polymer having the formula:  
       [Pr—Ar] n   (I)  
       wherein: 
 n is from about 30 to about 65;  
 Ar is a residue of an aromatic dihydroxy compound; and  
 Pr is a prepolymer which comprises: 
 from about 85 to about 95 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 15 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 2 mole % of a prepolymer component of formula T-G-T-G-T-G-T, wherein:  
 G is a residue of a polyol; and  
 T is a residue of a diisocyanate compound;  
 wherein in the preparation of the melt-spinnable elastomeric polymer, which preparation comprises combining together said polyol, said diisocyanate compound and said aromatic dihydroxy compound, said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide the melt-spinnable elastomeric polymer with substantially no higher melting polymeric component.  
 
 
     
     
         60 . A melt-spinnable elastomeric polymer according to  claim 59  which contains less than about 5% by weight of higher melting polymeric component.  
     
     
         61 . A melt-spinnable elastomeric polymer according to  claim 60  which contains less than about 4% by weight of higher melting polymeric component.  
     
     
         62 . A melt-spinnable elastomeric polymer according to  claim 61  which contains less than about 3% by weight of higher melting polymeric component.  
     
     
         63 . A melt-spinnable elastomeric polymer according to  claim 62  which contains less than about 2% by weight of higher melting polymeric component.  
     
     
         64 . A melt-spinnable elastomeric polymer according to  claim 63  which contains less than about 1% by weight of higher melting polymer.  
     
     
         65 . Pellets prepared from a melt-spinnable elastomeric polymer according to  claim 59 .  
     
     
         66 . A melt-spinnable elastomeric polymer comprising a diisocyanate-capped polyol prepolymer which is chain-extended with an aromatic dihydroxy compound, wherein in the preparation of the melt-spinnable elastomeric polymer, which preparation comprises combining together said polyol, said diisocyanate compound and said aromatic dihydroxy compound, said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide the melt-spinnable elastomeric polymer with substantially no higher melting polymeric component.  
     
     
         67 . A melt-spinnable elastomeric polymer according to  claim 66  wherein said preparation comprises: 
 (a) combining together said polyol and said diisocyanate compound to provide said prepolymer containing substantially no unreacted diisocyanate compound; and  
 (b) combining together said prepolymer and said aromatic dihydroxy compound to provide the melt-spinnable elastomeric polymer.  
 
     
     
         68 . A method for the preparation of a melt-spinnable elastomeric polymer having the formula:  
       [Pr—Ar] n   (I)  
       wherein: 
 n is from about 30 to about 65;  
 Ar is a residue of an aromatic dihydroxy compound; and  
 Pr is a prepolymer which comprises: 
 from about 85 to about 95 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 15 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 2 mole % of a prepolymer component of formula T-G-T-G-T-G-T, wherein:  
 G is a residue of a polyol; and  
 T is a residue of a diisocyanate compound;  
 wherein the method comprises combining together said aromatic dihydroxy compound, said polyol and said diisocyanate compound, said polyol and said diisocyanate compound being combined together in a mole ratio of about 1:2 to provide the melt-spinnable elastomeric polymer with substantially no higher melting polymeric component.  
 
 
     
     
         69 . A method for the preparation of a melt-spinnable elastomeric polymer which comprises a diisocyanate-capped polyol prepolymer which is chain-extended with an aromatic dihydroxy compound, wherein the method comprises combining together said polyol, said diisocyanate and said aromatic dihydroxy compound, wherein said polyol and said diisocyanate are combined together in a mole ratio of about 1:2 to provide the melt-spinnable elastomeric polymer with substantially no higher melting polymeric component.  
     
     
         70 . A method for the preparation of a melt-spinnable elastomeric polymer comprising: 
 (a) providing a diisocyanate-capped polyol prepolymer; and    (b) chain extending said prepolymer with an aromatic dihydroxy compound, wherein in the preparation of said prepolymer, said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide the melt-spinnable elastomeric polymer with substantially no higher melting polymeric component.    
     
     
         71 . A method according to  claim 70  comprising providing said prepolymer with substantially no unreacted diisocyanate compound.  
     
     
         72 . A prepolymer useful in the preparation of a melt-spinnable elastomeric polymer, wherein the prepolymer comprises: 
 from about 85 to about 95 mole % of a prepolymer component of formula T-G-T;    from about 3 to about 15 mole % of a prepolymer component of formula T-G-T-G-T; and    from 0 to about 2 mole % of a prepolymer component of formula T-G-T-G-T-G-T; wherein:    G is a residue of a polyol compound; and    T is a residue of a diisocyanate compound, wherein the prepolymer contains substantially no unreacted diisocyanate compound and wherein in the preparation of the prepolymer, said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide prepolymer which is useful in the preparation of melt-spinnable elastomeric polymer containing substantially no higher melting polymeric component.    
     
     
         73 . A prepolymer according to  claim 72  comprising: 
 from about 90 to about 94 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 7 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 1 mole % of a prepolymer component of formula T-G-T-G-T-G-T.  
 
     
     
         74 . A prepolymer according to  claim 73  comprising: 
 from about 92 to about 94 mole % of a prepolymer component of formula T-G-T;  
 from about 3 to about 5 mole % of a prepolymer component of formula T-G-T-G-T; and  
 from 0 to about 0.5 mole % of a prepolymer component of formula T-G-T-G-T-G-T.  
 
     
     
         75 . A diisocyanate-capped polyol prepolymer useful in the preparation of a melt-spinnable elastomeric polymer, wherein the prepolymer comprises a polyol which is capped with a diisocyanate compound and contains substantially no unreacted diisocyanate compound, and wherein in the preparation of the prepolymer, said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide prepolymer which is useful in the preparation of melt-spinnable elastomeric polymer containing substantially no higher melting polymeric component.  
     
     
         76 . A method for the preparation of a diisocyanate-capped polyol prepolymer useful for producing a melt-spinnable elastomeric polymer, wherein the method comprises: 
 (a) providing a polyol; and    (b) combining together with said polyol a diisocyanate compound to provide the prepolymer, wherein the prepolymer contains substantially no unreacted diisocyanate compound, and wherein said polyol and said diisocyanate compound are combined together in a mole ratio of about 1:2 to provide prepolymer which is useful in the preparation of melt-spinnable elastomeric polymer containing substantially no higher melting polymeric component.    
     
     
         77 . A textile article comprising fibers according to  claim 1 .  
     
     
         78 . A textile article according to  claim 77  which is selected from the group consisting of hosiery, pantyhose, panties and sportswear.  
     
     
         79 . A textile article according to  claim 78  which comprises pantyhose.

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