Multicomponent Fiber Containing a Polyarylene Sulfide

Abstract

A multicomponent fiber that contains two or more components arranged in distinct zones across the cross-section of the multicomponent fiber is provided. The components are arranged in a sheath/core configuration in which the core component is substantially surrounded by the sheath component. One of the sheath and the core is formed from a polyarylene sulfide composition and the other of the sheath and the core is formed from a thermoplastic composition that contains a thermoplastic polymer other than a polyarylene sulfide. Further, the polyarylene sulfide is “functionalized” in that it contains at least one functional group in its molecular structure (e.g., at its molecular terminal end). Without intending to be limited by theory, it is believed that such functional groups can improve the adhesion between the core and sheath components, thereby resulting in a fiber having improved thermal and mechanical properties.

What is claimed is: 
     
         1 . A multicomponent fiber that comprises a sheath component that substantially surrounds a core component, wherein one of the core component and the sheath component is formed from a polyarylene sulfide composition that comprises a functionalized polyarylene sulfide, and wherein the other of the sheath component and the core component is formed from a thermoplastic composition that contains a thermoplastic polymer other than a polyarylene sulfide. 
     
     
         2 . The multicomponent fiber of  claim 1 , wherein the core component is formed from the polyarylene sulfide composition and the sheath component is formed from the thermoplastic composition that contains a thermoplastic polymer other than a polyarylene sulfide. 
     
     
         3 . The multicomponent fiber of  claim 1 , wherein the sheath component is formed from the polyarylene sulfide composition and the core component is formed from the thermoplastic composition that contains a thermoplastic polymer other than a polyarylene sulfide. 
     
     
         4 . The multicomponent fiber of  claim 1 , wherein the functionalized polyarylene sulfide is a functionalized polyphenylene sulfide. 
     
     
         5 . The multicomponent fiber of  claim 1 , wherein the functionalized polyarylene sulfide contains at least one functional group in its molecular structure. 
     
     
         6 . The multicomponent fiber of  claim 5 , wherein the functional group is an epoxy group, hydroxyl group, carboxyl, acrylate group, carbonate group, amino group, nitro group, or a combination thereof. 
     
     
         7 . The multicomponent fiber of  claim 5 , wherein the functional group is introduced by reacting a base polyarylene sulfide with a functional disulfide compound. 
     
     
         8 . The multicomponent fiber of  claim 7 , wherein the disulfide compound has the following general structure:
   R 1 —S—S—R 2  
   wherein R 1  and R 2  are independently hydrocarbon groups that include from 1 to about 20 carbons, and wherein at least one of R 1  and R 2  has a reactive functionality.   
     
     
         9 . The multicomponent fiber of  claim 7 , wherein the disulfide compound is 2,2′-diaminodiphenyl disulfide, 3,3′-diaminodiphenyl disulfide, 4,4′-diaminodiphenyl disulfide, dibenzyl disulfide, dithiosalicyclic acid, dithioglycolic acid, α,α′-dithiodilactic acid, β,β′-dithiodilactic acid, 3,3′-dithiodipyridine, 4,4′-dithiomorpholine, 2,2′-dithiobis(benzothiazole), 2,2′-dithiobis(benzimidazole), 2,2′-dithiobis(benzoxazole), 2-(4′-morpholinodithio)benzothiazole, or a combination thereof. 
     
     
         10 . The multicomponent fiber of  claim 1 , wherein the polyarylene sulfide composition contains from about 60 wt. % to 100 wt. % of functionalized polyarylene sulfides. 
     
     
         11 . The multicomponent fiber of  claim 1 , wherein the thermoplastic polymer has a melting point of about 150° C. or more. 
     
     
         12 . The multicomponent fiber of  claim 1 , wherein the thermoplastic polymer is an aromatic polyester, aliphatic polyester, polyamide, polyolefin, or a combination thereof. 
     
     
         13 . The multicomponent fiber of  claim 1 , wherein the thermoplastic composition comprises from about 60 wt. % to 100 wt. % of thermoplastic polymers. 
     
     
         14 . The multicomponent fiber of  claim 1 , wherein the thermoplastic composition further comprises a UV blocker. 
     
     
         15 . The multicomponent fiber of  claim 1 , wherein the thermoplastic composition is generally free of polyarylene sulfides. 
     
     
         16 . The multicomponent fiber of  claim 1 , wherein the sheath and core components are arranged in a concentric configuration. 
     
     
         17 . The multicomponent fiber of  claim 1 , wherein the sheath and core components are arranged in an eccentric configuration. 
     
     
         18 . The multicomponent fiber of  claim 1 , wherein the fiber has an islands-in-the-sea configuration in which the sea is the sheath component and the islands are the core component. 
     
     
         19 . The multicomponent fiber of  claim 1 , wherein the fiber has a multilobal configuration in which arms extend outwardly from a central portion, wherein the sheath component forms the arms and the core component forms the central portion. 
     
     
         20 . The multicomponent fiber of  claim 1 , wherein the fiber is a bicomponent fiber. 
     
     
         21 . The multicomponent fiber of  claim 1 , wherein the core component constitute from about 30 wt. % to about 99 wt. % of the fiber and the sheath component constitutes from about 1 wt. % to about 70 wt. % of the fiber. 
     
     
         22 . A fibrous material comprising the multicomponent fiber of  claim 1 .